Indian Jugaad Technology (Frugal Engineering)
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Indian Juggad Technology (FRUGAL ENGINEERING)
Achieving more with Fewer ResourcesS.J.A. Rizvi
Assistant ProfessorDepartment of Petroleum Studies
Aligarh Muslim University, [email protected]
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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."
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Engineering
Frugal is an engineering philosophy
Stream Philosophy
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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.
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Juggad Engineering: In its crude form
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Juggad Engineering: In its Refined form
Somaiya College students have designed a vehicle they claim can run 300 kmpl.
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What is Essential for Frugal Engineering?
1. Common Sense2. Common Sense3. Common Sense
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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
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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
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Practicing Frugal Engineering
The Philosophy
It Is Easier To Want What You Get, Than To Get What You want.
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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
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Explore Your SurroundingScan Your Mind for any better Alternate use
Learn from a child
They are BIGGEST EXPLORER
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The frugal way
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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.
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Believe in yourself,
Keep patience
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Don't get emotionally
attached to your innovation,
One day you or somebody else will
change it.
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Every act of creation is
first of all,
An act of destruction
Pablo Picasso
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Analysis Paralysis
Action without Vision
Avoid
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Theory vs. Practice
In theory, there is no difference between theory
and practice. But in practice there is.
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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
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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
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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.
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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.
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Some of my work
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Tester for Electricians
Advantages;
1. Extremely simple2. Low cost3. Easy to carry 4. Reliable result Drawbacks;
1. Difficulty in continuity testing.
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Alternate design
Additional
1. Two pin Plug (male/female assembly)
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Parallel Testing
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Continuity Testing
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Servo motor Torque Estimation
Calculation Result = 18 N.m Servo motor Cost = 2.5 lakhs
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Torque Estimation: The Frugal way
Calculation Result = 9.1 N.m
Servo motor Cost = 1.45 lakhs
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It is working perfectly
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Microcellular Compression Moulding Machine from Universal Testing Machine (UTM)
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Results of Microcellular Compression Moulding Machine
SEM Micrographs
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Conversion of Microcellular Injection Moulding Machine in a Capillary Remoter
Microcellular Injection Moulding Machine
Capillary Rheometer
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Rheology of Polymer/ gas Solution
Development of Injection Molding Rheometer (IMR)
Basic Assumption
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Equations
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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
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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
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Viscosity Model for polystyrene/ N2 Solution at 220°C
Truncated Power Law
Model
Bird-Carreau Model
n1
n2
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Supercritical gas Injector
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Complete Setup
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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.
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The Frugal Engineering Approach
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SCF Injector Assembly
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• 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
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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