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Ch58-I044963.fm Page 292 Tuesday, August 1, 2006 4:39 PM
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TABLE 1
COMPOSITION OF PHYSICAL PARAMETERS
Cateaorv Number of items
Quality 9
Cost & safety 4
Raw material 3
Cuttinq 6
Heatinq 6
Forqinq 42
Trimminq 16
Thermal refininq 5
Shot blast 4
Total 95

Task groups
Task order Task order
TaskB TaskD Task A Ip Taskl TaskG Task B Task D TaskH Taskl TaskG Task E Task A TaskF o
i =
TaskB 0 0 M o d 0 0 0 TaskB 0 0 0 0 0 0 0 0
TaskD • 0 -p Ms ol 0 0 TaskD • n n n n n n 0 n
TaskE 0 • i p /° 0 0 0 TaskH 0 • 1 1 0 0 0 0
Task A 0 • 1 l)| 0 U Taskl 0 T 1 I 1 0 0 0 0
i
TaskF 0 i - 9 • 0 0 0 TaskG 0 1 1 1 10 0 0 0
ft ft iy TaskE 0 I 0 0 10 • I 1 0 0
TaskH 0 0 0 1 0 1 1 Task A 0 0 0 0 1 1
Taskl 0 0 0 o o 4 • 1 1 1 Task F 0 0 0 0 I i -o • 4 i
TaskG 0 0 0 0| 1 TaskC 0 0 0 0 0 0 1 1
°l <|| I 1 •1
a) Without use of essential constraints b) With use of essential constraints
Figure 6: Efficiency by considering essential constraints

CONCLUSION
The new technique does not start with the existing tasks, but with the physical cause-effect relations
between designed, adjusted, intermediate and goal variables. These physical relations are described in
the relation diagram. Required tasks are generated based on these physical cause-effect relations. The
proposed technique was evaluated using a hot forging trial process that includes 95 physical variables.
An improvement of the lead time of around 40% was realized using a process optimization with the
essential constraints, as compared to the sequential trial.

REFERENCES
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Sato S., Inamori Y., Nakano M., Suzuki T. and Miyajima N. (2005). Analysis Method for Overseas
Production Preparation Process. Journal of Japan Society of Mechanical Engineering 71:705,
322-329.
Yassine A., Falkenburg D. and Chelst K. (1999). Engineering Design Management: An Information
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