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How I Built an Electricity Producing Wind TurbineSeveral years ago I bought some remote property in Arizona. I am an astronomer and wanted a place to practice my hobby far away from the terrible light pollution found near cities of any real size. I found a great piece of property. The problem is, it's so remote that there is no electric service available. That's not really a problem. No electricity equals no light pollution. However, it would be nice to have at least a little electricity, since so much of life in the 21st century is dependent on it.One thing I noticed right away about my property is that most of the time, the wind is blowing. Almost from the moment I bought it, I had the idea of putting up a wind turbine and making some electricity, and later adding some solar panels. This is the story of how I did it. Not with an expensive, store-bought turbine, but with a home-built one that cost hardly anything. If you have some fabricating skills and some electronic know-how, you can build one too.Step 1: Acquiring a GeneratorI started by Googling for information on home-built wind turbines. There are a lot of them out there in an amazing variety of designs and complexities. All of them had five things in common though:1. A generator2. Blades3. A mounting that keeps it turned into the wind4. A tower to get it up into the wind5. Batteries and an electronic control systemI reduced the project to just five little systems. If attacked one at a time, the project didn't seem too terribly difficult. I decided to start with the generator. My online research showed that a lot of people were building their own generators. That seemed a bit too complicated, at least for a first effort. Others were using surplus permanent magnet DC motors as generators in their projects. This looked like a simpler way to go. So I began looking into what motors were best for the job.A lot of people seemed to like to use old computer tape drive motors (surplus relics from the days when computers had big reel to reel tape drives). The best apparently are a couple of models of motor made by Ametek. The best motor made by Ametek is a 99 volt DC motor that works great as a generator. Unfortunately, they are almost impossible to locate these days. There are a lot of other Ametek motors around though. A couple of their other models make decent generators and can still be found on places like Ebay. This web site talks about the virtues and vices of various Ametek motors when used as generators.I managed to score one of the good 30 volt Ametek motors off of Ebay for only $26. They don't go that cheap these days. People are catching on to the fact that they make great wind generators. Other brands will work, so don't fret about the price Ameteks are going for. Shop wisely. Anyway, The motor I got was in good shape and worked great. Even just giving the shaft a quick turn with my fingers would light a 12 volt bulb quite brightly. I gave it a real test by chucking it up in my drill press and connecting it to a dummy load. It works great as a generator, putting out easily a couple hundred Watts with this setup. I knew then that if I could make a decent set of blades to drive it, it would produce plenty of power.Step 2: Making the BladesBlades and a hub to connect them to were the next order of business. More online research ensued. A lot of people made their own blades by carving them out of wood. That looked like an outrageous amount of work to me. I found that other people were making blades by cutting sections out of PVC pipe and shaping them into airfoils. That looked a lot more promising to me. This web site tells you how to make a set of blades for a small wind turbine using PVC pipe.I followed their general recipe. I did things a little differently though. I used black ABS pipe since my local homecenter store just happened to have pre-cut lengths of it. I used 6 inch pipe instead of 4 inch and 24 inches long instead of 19 5/8. I started by quartering a 24 inch long piece of pipe around its circumference and cutting it lengthwise into four pieces. Then I cut out one blade, and used it as a template for cutting out the others. That left me with 4 blades (3 plus one spare).I then did a little extra smoothing and shaping using my belt sander and palm sander on the cut edges to try to make them into better airfoils. I don't know if it's really much of an improvement, but it didn't seem to hurt, and the blades look really good (if I do say so myself).Step 3: Building the HubNext I needed a hub to bolt the blades to and attach to the motor. Rummaging around in my workshop, I found a toothed pulley that fit on the motor shaft, but was a little too small in diameter to bolt the blades onto. I also found a scrap disk of Aluminum 5 inches in diameter and 1/4 inch thick that I could bolt the blades onto, but wouldn't attach to the motor shaft. The simple solution of course was to bolt these two pieces together to make the hub. Much drilling, tapping and bolting later, I had a hub.Step 4: Building the Turbine MountingNext I needed a mounting for the turbine. Keeping it simple, I opted to just strap the motor to a piece of 2 X 4 wood. The correct length of the wood was computed by the highly scientific method of picking the best looking piece of scrap 2 X 4 off my scrap wood pile and going with however long it was. I also cut a piece of 4 inch diameter PVC pipe to make a shield to go over the motor and protect it from the weather. For a tail to keep it turned into the wind, I again just used a piece of heavy sheet Aluminum I happened to have laying around. I was worried that it wouldn't be a big enough tail, but it seems to work just fine. The turbine snaps right around into the wind every time it changes direction. I have added a few dimensions to the picture. I doubt any of these measurements is critical though.Next I had to begin thinking about some sort of tower and some sort of bearing that would allow the head to freely turn into the wind. I spent a lot of time in my local homecenter stores (Lowes and Home Depot) brainstorming. Finally, I came up with a solution that seems to work well. While brainstorming, I noticed that 1 inch diameter iron pipe is a good slip-fit inside 1 1/4 inch diameter steel EMT electrical conduit. I could use a long piece of 1 1/4 inch conduit as my tower and 1 inch pipe fittings at either end. For the head unit I attached a 1 inch iron floor flange centered 7 1/2 inches back from the generator end of the 2X4, and screwed a 10 inch long iron pipe nipple into it. The nipple would slip into the top of the piece of conduit I'd use as a tower and form a nice bearing. Wires from the generator would pass through a hole drilled in the 2X4 down the center of the pipe/conduit unit and exit at the base of the tower. Brilliant! (if I do say so myself).Step 5: Build the Tower BaseFor the tower base, I started by cutting a 2 foot diameter disk out of plywood. I made a U shaped assembly out of 1 inch pipe fittings. In the middle of that assembly I put a 1 1/4 inch Tee. The Tee is free to turn around the 1 inch pipe and forms a hinge that allows me to raise and lower the tower. I then added a close nipple, a 1 1/4 to 1 reducing fitting, and a 12 inch nipple. Later I added a 1 inch Tee between the reducer and the 12 inch nipple so there would be a place for the wires to exit the pipe. This is shown in a photo further down the page. I also later drilled holes in the wooden disk to allow me to use steel stakes to lock it in place on the ground.The second photo shows the head and base together. You can begin to see how it will go together. Imagine a 10 foot long piece of steel conduit connecting the two pieces. Since I was building this thing in Florida, but was going to use it in Arizona, I decided to hold off on purchasing the 10 foot piece of conduit until I got to Arizona. That meant the wind turbine would never be fully assembled and not get a proper test until I was ready to put it up in the field. That was a little scary because I wouldn't know if the thing actually worked until I tried it in Arizona.Step 6: Paint All the Wood PartsNext, I painted all the wooden parts with a couple of coats of white latex paint I had leftover from another project. I wanted to protect the wood from the weather. This photo also shows the lead counterweight I added to the left side of the 2X4 under the tail to balance the head.Step 7: The Finished Head of the Wind TurbineThis photo shows the finished head unit with the blades attached. Is that a thing of beauty or what? It almost looks like I know what I'm doing.I never got a chance to properly test the unit before heading to Arizona. One windy day though, I did take the head outside and hold it high up in the air above my head into the wind just to see if the blades would spin it as well as I had hoped. Spin it they did. In a matter of a few seconds it spun up to a truly scary speed (no load on the generator), and I found myself holding onto a giant, spinning, whirligig of death, with no idea how to put it down without getting myself chopped to bits. Fortunately, I did eventually manage to turn it out of the wind and slow it down to a non-lethal speed. I won't make that mistake again.Step 8: Build the Charge ControllerNow That I had all the mechanical parts sorted out, it was time to turn toward the electronic end of the project. A wind power system consists of the wind turbine, one or more batteries to store power produced by the turbine, a blocking diode to prevent power from the batteries being wasted spinning the motor/generator, a secondary load to dump power from the turbine into when the batteries are fully charged, and a charge controller to run everything.There are lots of controllers for solar and wind power systems. Anyplace that sells alternative energy stuff will have them. There are also always lots of them for sale on Ebay . I decided to try building my own though. So it was back to Googling for information on wind turbine charge controllers. I found a lot of information, including some complete schematics, which was quite nice, and made building my own unit very easy. I based my unit on the schematic of the one found on this web site:http://www.fieldlines.com/story/2004/9/20/0406/27488That web site goes into a lot of detail about the controller, so I'm only going to talk about it in fairly general terms here. Again, while I followed their general recipe, I did do some things differently. Being an avid electronics tinkerer from an early age, I have a huge stock of electronic components already on hand, so I had to buy very little to complete the controller. I substituted different components for some parts and reworked the circuit a little just so I could use parts I already had on hand. That way I had to buy almost nothing to build the controller. The only part I had to buy was the relay. I built my prototype charge controller by bolting all the pieces to a piece of plywood, as seen in the first photo below. I would rebuild it in a weatherproof enclosure later.Whether you build your own, or buy one, you will need some sort of controller for your wind turbine. The general principal behind the controller is that it monitors the voltage of the battery(s) in your system and either sends power from the turbine into the batteries to recharge them, or dumps the power from the turbine into a secondary load if the batteries are fully charged (to prevent over-charging and destroying the batteries). The schematic and write-up on the above web page does a good job of explaining it.In operation, the wind turbine is connected to the controller. Lines then run from the controller to the battery. All loads are taken directly from the battery. If the battery voltage drops below 11.9 volts, the controller switches the turbine power to charging the battery. If the battery voltage rises to 14 volts, the controller switches to dumping the turbine power into the dummy load. There are trimpots to adjust the voltage levels at which the controller toggles back and forth between the two states. I chose 11.9V for the discharge point and 14V for the fully charged point based on advice from lots of different web sites on the subject of properly charging lead acid batteries. The sites all recommended slightly different voltages. I sort of averaged them and came up with my numbers. When the battery voltage is between 11.9V and 14.8V, the system can be switched between either charging or dumping. A pair of push buttons allow me to switch between states anytime, for testing purposes. Normally the system runs automatically. When charging the battery, the yellow LED is lit. When the battery is charged and power is being dumped to the the dummy load, the green LED is lit. This gives me some minimal feedback on what is going on with the system. I also use my multimeter to measure both battery voltage, and turbine output voltage. I will probably eventually add either panel meters, or automotive-style voltage and charge/discharge meters to the system. I'll do that once I have it in some sort of enclosure.I used my variable voltage bench power supply to simulate a battery in various states of charge and discharge to test and tune the controller. I could set the voltage of the power supply to 11.9V and set the trimpot for the low voltage trip point. Then I could crank the voltage up to 14V and set the trimpot for the high voltage trimpot. I had to get it set before I took it into the field because I'd have no way to tune it up out there.I have found out the hard way that it is important with this controller design to connect the battery first, then connect the wind turbine and/or solar panels. If you connect the wind turbine first, the wild voltage swings coming from the turbine won't be smoothed out by the load of the battery, the controller will behave erratically, the relay will click away wildly, and voltage spikes could destroy the ICs. So always connect to the battery(s) first, then connect the wind turbine. Also, make sure you disconnect the wind turbine first when taking the system apart. Disconnect the battery(s) last.Step 9: Erect the TowerAt last, all parts of the project were complete. It was all done only a week before my vacation arrived. That was cutting it close. I disassembled the turbine and carefully packed the parts and the tools I'd need to assemble it for their trip across the country. Then I once again I drove out to my remote property in Arizona for a week of off-grid relaxation, but this time with hopes of having some actual electricity on the site.The first order of business was setting up and bracing the tower. After arriving at my property and unloading my van, I drove to the nearest Home Depot (about 60 miles one way) and bought the 10 foot long piece of 1 1/4 inch conduit I needed for the tower. Once I had it, assembly went quickly. I used nylon rope to anchor the pole to four big wooden stakes driven in the ground. Turnbuckles on the lower ends of each guy-line allowed my to plumb up the tower. By releasing the line from either stake in line with the hinge at the base, I could raise and lower the tower easily. Eventually the nylon line and wooden stakes will be replaced with steel stakes and steel cables. For testing though, this arrangement worked fine.The second photo shows a closeup of how the guy-lines attach near the top of the tower. I used chain-link fence brackets as tie points for my guy-lines. The fence brackets don't quite clamp down tightly on the conduit which is smaller in diameter than the fence posts they are normally used with. So there is a steel hose clamp at either end of the stack of brackets to keep them in place.The third photo shows the base of the tower, staked to the ground, and with the wire from the wind turbine exiting from the Tee below the conduit tower. I used an old orange extension cord with a broken plug to connect between the turbine and the controller. I simply cut both ends off and put on spade lugs. Threading the wire through the tower turned out to be easy. It was a cold morning and the cord was very stiff. I was able to just push it through the length of the conduit tower. on a warmer day I probably would have had to use a fishtape or string line to pull the cord through the conduit. I got lucky.Step 10: Erect the Wind TurbineThe first photo shows the turbine head installed on top of the tower. I greased up the pipe on the bottom of the head and slid it into the top of the conduit. It made a great bearing, just as I'd planned. Sometimes I even amaze myself.Too bad there was nobody around to get an Iwo Jima Flag Raising type picture of me raising the tower up with the head installed.The second photo shows the wind turbine fully assembled. Now I'm just waiting for the wind to blow. Wouldn't you know it, it was dead calm that morning. It was the first calm day I had ever seen out there. The wind had always been blowing every other time I had been there. Well, nothing to do but wait.Finally! The wind was up and the turbine was spinning, and the lovely electricity is is starting to be produced.Step 11: Connect the ElThe first photo below shows the electronics setup. The battery, inverter, meter and prototype charge controller are all sitting on a plywood board on top of a blue plastic tub. I plug a long extension cord into the inverter and run power back to my campsite.Once the wind starts blowing, the turbine head snaps around into it and begins spinning up. It spins up quickly until the output voltage exceeds the battery voltage plus the blocking diode drop (around 13.2 volts, depending on the state of the battery charge). it is really running without a load until that point. Once the that voltage is exceeded, the turbine suddenly has a load as it begins dumping power into the battery. Once under load, the RPMs only slightly increase as the wind speed increases. More wind means more current into the battery which means more load on the generator. So the system is pretty much self-governing. I saw no signs of over-reving. Of course in storm-force winds, all bets are off.Switching the controller to dump power into the dummy load did a good job of braking the turbine and slowing it way down even in stronger gusts. Actually shorting the turbine output is an even better brake. It brings the turbine to a halt right now, even in strong winds. Shorting the output is how I made the turbine safe to raise and lower, so I wouldn't get sliced and diced by the spinning blades. Warning though, the whole head assembly can still swing around and crack you hard on the noggin if the wind changes direction while you are working on these things. So be careful out there.

By DMAIC OR DFSS,DMADV Method of Lean sixsigma we can solve following six sigma projects .A. Engineers…Examples of six sigma projects: 1. six sigma project: rail car cycle time. Define: Eliminate paying extra demurrage charges on rail cars. Measure: Paying over four days demurrage on some rail cars. Any demurrage charge over the allowed is a defect. Analyze: Rail car traffic, switch engine schedule, rail company operating rules, operating company procedures, spotting procedures. Improve: Changed sequences of handling empty and full cars. Modified loading times by less than 2 hrs. Result is essentially no demurrage, over the allowed, for the entire site. Control: Rail company changed procedures and operating company changed scheduling practices. 2. Six sigma project: chemical plant bottleneck. Define: Distillation tower has internal damage limiting production rates. Next outage is scheduled in one year. If outage taken now to repair damage we will still have to take outage in one year because of parts delivery for other essential projects. Measure: At anything over 85% of capacity the distillation tower will not perform. With six months of effort, Operations Engineers and Process Engineering could find no solution other than to take an early outage. Anything less than 100% capacity is considered a defect. Analyze: Identified key operating variables, established allowable ranges for each, and conducted a Designed Experiment. Improve: A single set of conditions allowed operations at 102% of capacity without problems. At that level another part of the plant became the bottleneck. Increased capacity until scheduled outage worth $6million. Control: All shift operators were trained for new conditions and the operations procedures were modified. 3. Six sigma project: retail display. Define: Marketing has designed a "fancy" display unit that they think will outperform the "standard" display unit and they want to put one in every store. "Fancy" display is 10X cost of a "standard" display and all stores already have "standard" units. Should the new displays be purchased. Measures: Have data for each store on sales of this product for every day. Analyze: The stores identified at least three other factors besides display type that could impact sales. Range for each factor was identified. Design of Experiments was conducted. Improve: "Fancy" display had no significant impact on sales. The "fancy" displays were not ordered for any more stores, with considerable cost savings. Control: Future changes will be tested and evaluated using statistical techniques. 4. Six sigma project: water treating. Define: Water treating unit in 15 years had never been able to handle the nameplate capacity. Treatment chemical costs were higher than other types of treatment units. Measure: Confirmed flow rate through the system vs. nameplate. Analyze: Measure system evaluation and found many measurements that were off by over 100%. Hourly operations identified key variables in the operation of the unit and the acceptable range of each. Conducted three different Designed Experiments. Improve: Corrected the measurement problems. Found set of operating variables that produced 107% of nameplate capacity at higher quality with lower chemical use. Chemical use reduced by $180K per year. Control: Hourly operations trained, procedures modified, process to check measurement instituted. Model for changes in inlet water conditions. 5. Six sigma project: power distribution reliability. Define: Large chemical site had significant losses due to power outages. Measure: Dollar value determined for each failure and the total. Each failure was assigned to a major component. Analyze: Mapped the entire system by major component and identified failure rates for each major component. Found areas with projects scheduled that were very unlikely to fail and would add nothing to overall reliability. Other components were being ignored and had a highly likelihood of causing an outage. Improve: Developed plan for each component depending upon failure mode and frequency for that component. Made a 10X reduction in the dollar losses due to power failures on site. Control: Track each major component and modify action plan based on failure mode if needed. System shared with other locations. 6. Six sigma project: redundant analysis. Define: Analysis is being conducted at two and three locations for the same product with different results from each location. Capital requests from multiple area for the same analysis for the same material. Measure: For each analysis collected the corresponding results from each location. Totaled the capital request for analysis where they were already being done or duplicate requests for the same analysis. Analyze: In some cases the methods were the same and the brand of instrument the same, some had the same type of instrument but different brand and different procedures, in others different types of instruments were being used. Found over calibration of most instruments. Sources of variation for each type of analysis were investigated using Design of Experiments. Improve: Real time telemetry of data eliminated some redundancy. For other analysis correlation curves had to be developed to show the equivalent values for different methods and agreement was reached to use one analysis and share the results. Totally eliminated the significant capital request for analysis. Control: Modified capital authorization request procedure. Control charts for each analysis to determine when to calibrate. 7. Six sigma project: new capacity justified. Define: Contract to deliver product at a minimum rate on a daily basis. Severe penalties if rate missed by even a small amount. Customer "good will" also an issue. Measure: Capacity of units in the system more than the minimum rates. Collected failure rate data for each unit and time to repair. Analyze: Failure rate data combined with the time to repair data indicated that there were significant periods of time when the minimum contract rates could not be met and penalties would be paid. Improve: Capital approved for an additional unit. Within the first year the new unit was required at least four separate times for several weeks each time to meet the contract minimums. Any one of the four times returned enough cash to pay for all of the capital expended. Control: System to track and monitor failure data and repair time data. 8. Six sigma project: people selection. Define: Why is there such a difference in the sales performance of people? Measure: Top people have 10X volume of the bottom 25%. Failure to meet sales quotas is a defect. Analyze: Education, training, time in job, product line, sales area, profiles. Improve: Able to identify by profile 72% of the top sales people. Use this tool to select new people into this function. Control: Use profiles for new hires and continue to monitor performance levels. 9. Six sigma project: parts failing after final machines. Define: Inspection is rejecting a high number of parts after final machines. Measure: Product yield was determined and number of defects in total to establish defect yield and sigma value. Analyze: Machine operators, engineers and vendor identified variables that could impact the production of defects. Range of acceptable levels determined for each variable. Five different Designed Experiments were conducted. Improve: Operating instructions changed to the conditions with the lowest defect production consistent with capacity limits. Final product yield increased 13%. Control: Control charts installed for each machine. Decision tree corrective action plan provided for known defects and known corrective actions. 10. Six sigma project: out of specification product. Define: Amount of product out of specification (spec) and being automatically removed is high. No recycle or salvage value. Measure: Quantified the amount of out of spec product for each product grade. Analyze: Operations and Engineers identified the variables that impact the production of out of spec material. Several of these are preventive actions performed by operations. Ranges for the levels and frequencies for the variables were determined. Designed Experiments were run and acceptable levels and frequencies determined. Improve: Levels for the variables and frequencies for operator preventive actions established. Out of spec material dropped by 50%. Control: Operating procedures were modified, schedules for operator corrective actions instituted, and control charts for the amount of out spec material are being kept. 11. Six sigma project: engineering changes. Define: Large number of changes from client after approving engineering design. Schedule slipping. Measure: Number of changes, time involved in changes, compliance to critical path schedule. Analyze: No clear authority on client team to establish scope, any of client team could make changes, verbal communication of changes, conflicting changes by client team members. Language issues between client and engineers. Improve: Regular engineering/client meetings where topics included: scope for each section and desired objective, known limitations defined, unclear requirements were questioned and options discussed. Written plan signed by client representative and engineering lead. Change requests in writing and signed by client representative. Changes decrease by factor of 4.7 and schedule met. Control: Change requests all in writing. Shared approach with other disciplines on project. 12. Six sigma project: web design. Define: Design a web site that ranks in the top ten (10) on all major search engines and directories. Measure: Enter "six sigma" and check ranking in search engines. Analyze: URL name, title of pages, and other factors are major ranking criteria. Reciprocal links and other routine activities aid in search engine ranking. Improve: Purchase URL with six sigma included, optimize each page, develop reciprocal links, and perform other regular activities required to maintain traffic and ranking. Control: Monitor ranking on search engines weekly. You can check on the success of this project by entering "six sigma" in the search field of your favorite search engine. The titles and descriptions may vary , the URL link is the performance measureB.For MBA HR …Reduce the time required to hire an employee • Improve employee on-boarding and orientation processes • Reduce expenditures for Recruitment • Improve timeliness and the value of employee performance reviews • Reduce absenteeism • Improve training efficiency • Improve employee satisfaction • Identify and correct retention issues • Reduce Incentive Compensation errors • Eliminate Overpayments to Terminated Salaried Employees • Improving grievance handling process. • Consolidation of employee information databases • Integration of multiple payroll systems for remote locations • Increase job posting hit rate • Design of job posting templates for recruiters • Increase retention using exit interview informationDecrease number of days to respond to applicant • Use of technicians for some functions performed by engineers • Decrease use of full security checks when not necessary • Improved learning module design with self-evaluation sections • Catalog of available modules for self-learning • 100% use of off-site safety audits • Approved generic drug list • Lowering turnover Lost Time / Safety Reducing injuries at work Improving recruiting time-to-fill Quality of our Expertise / Tech. Ability. Quality of Employee Attendance. Quality of Employee Training / Development. Quality of Employee Morale. Quality of Employee Retention. & Many more …..C.For MBA MARKETING …Focuses on customers and processes · Achieves bottom-line results · Driven by a well defined project selection criteria · Utilizes clearly defined measures of success · Achieves quantifiable financial returns · Uses a disciplined, multifunctional project approach (DMAIC) · Executes projects with manageable completion times (3-6 months per project)· Employs a well-trained team of Champions, Black Belts, and Green Belts. Benefits of Six Sigma Projects Include: · Increased customer satisfaction · Improved profitability by eliminating defects (reduced cost of poor quality) · Enhanced productivity · Reduced cycle times (leading to better customer service) · Improved product and service offeringsD.For MBA FINANCE …Common Lean Six Sigma Implementation in Finance and Banking are listed below.Reducing Financial Risk • Simulation for financial decisions • New product design of financial instruments • Improving portfolio strategy • On operational level - • Reducing documentation errors • Improving the reconciliation processes. • Reducing response delays. • Reducing or eliminating invoicing errors • Eliminating the possibility of erroneous data entry • Reducing audit non conformities. • Reducing salary issue turn around time • Control spending over time • Reduce electronic financial transaction costs. • Reducing complaints. • Enhancing (internal or external) customer satisfaction •Improving customer feedback and response processesE.Loan DepartmentReducing the cycle time to Process a Loan Application (both Mortgage & Personal loans). 2. Improving the Customer Information gathering processes. 3. Improving the Credit Evaluation Process 4. Improving Productivity of loan processing agents.F.Account Opening1Reducing the time to open an account 2. Reducing errors in account opening process. 3. Reducing rework in processing customer applications .G.Other Projects in Retail Banking1. Reducing the Credit Card Delivery time. 2. Reducing Bank Statements Processing & Delivery time. 3. Reducing the errors in money transfer 4. Improving accuracy, timeliness and completeness of customer communication. 5. Developing new products (timeliness, business potential) 6. Improving Market Share of existing banking products. 7. Improving the Branch Banking Processes