Search results for: hardwood lumber manufacturing process

Authors: N. K. A. M. Galvão, A. Godoy Jr., A. L. J. Pereira, G. V. Martins, R. S. Pessoa, H. S. Maciel, M. A. Fraga

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Silicon carbide (SiC) is a wide band-gap semiconductor material with very attractive properties, such as high breakdown voltage, chemical inertness, and high thermal and electrical stability, which makes it a promising candidate for several applications, including microelectromechanical systems (MEMS) and electronic devices. In MEMS manufacturing, the etching process is an important step. It has been proved that wet etching of SiC is not feasible due to its high bond strength and high chemical inertness. In view of this difficulty, the plasma etching technique has been applied with paramount success. However, in most of these studies, only the determination of the etching rate and/or morphological characterization of SiC, as well as the analysis of the reactive ions present in the plasma, are lowly explored. There is a lack of results in the literature on the chemical and structural properties of SiC after the etching process [4]. In this work, we investigated the etching process of sputtered amorphous SiC thin films on Si substrates in a reactive ion etching (RIE) system using sulfur hexafluoride (SF6) gas under different RF power. The results of the chemical and structural analyses of the etched films revealed that, for all conditions, a SiC crystallization occurred, in addition to fluoride contamination. In conclusion, we observed that SiC crystallization is a side effect promoted by structural, morphological and chemical changes caused by RIE SF6 etching process.

Keywords: plasma etching, plasma deposition, Silicon Carbide, microelectromechanical systems

Procedia PDF Downloads 56

Authors: Monika Balach, Iwona Frydrych, Agnieszka Cichocka

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The objective of this research is to develop an algorithm, taking into account material type and body type that will describe the fabric properties and quality of fit of a garment to the body. One of the objectives of this research is to develop a new algorithm to simulate cloth draping within CAD/CAM software. Existing virtual fitting does not accurately simulate fabric draping behaviour. Part of the research into virtual fitting will focus on the mechanical properties of fabrics. Material behaviour depends on many factors including fibre, yarn, manufacturing process, fabric weight, textile finish, etc. For this study, several different fabric types with very different mechanical properties will be selected and evaluated for all of the above fabric characteristics. These fabrics include woven thick cotton fabric which is stiff and non-bending, woven with elastic content, which is elastic and bends on the body. Within the virtual simulation, the following mechanical properties can be specified: shear, bending, weight, thickness, and friction. To help calculate these properties, the KES system (Kawabata) can be used. This system was originally developed to calculate the mechanical properties of fabric. In this research, the author will focus on three properties: bending, shear, and roughness. This study will consider current research using the KES system to understand and simulate fabric folding on the virtual body. Testing will help to determine which material properties have the largest impact on the fit of the garment. By developing an algorithm which factors in body type, material type, and clothing function, it will be possible to determine how a specific type of clothing made from a particular type of material will fit on a specific body shape and size. A fit indicator will display areas of stress on the garment such as shoulders, chest waist, hips. From this data, CAD/CAM software can be used to develop garments that fit with a very high degree of accuracy. This research, therefore, aims to provide an innovative solution for garment fitting which will aid in the manufacture of clothing. This research will help the clothing industry by cutting the cost of the clothing manufacturing process and also reduce the cost spent on fitting. The manufacturing process can be made more efficient by virtual fitting of the garment before the real clothing sample is made. Fitting software could be integrated into clothing retailer websites allowing customers to enter their biometric data and determine how the particular garment and material type would fit their body.

Keywords: 3D scanning, fabric mechanical properties, quality of fit, virtual fitting

Procedia PDF Downloads 149

Authors: Bahaa Eltahawy, Mikko Ylihärsilä, Reino Virrankoski, Esko Petäjä

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Sheet metal processing is automated, but the step from product models to the production machine control still requires human intervention. This may cause time consuming bottlenecks in the production process and increase the risk of human errors. In this paper we present a system, which automatically recognizes features from the CAD-model of the sheet metal product. By using these features, the system produces a complete model of the particular sheet metal product. Then the model is used as an input for the sheet metal processing machine. Currently the system is implemented, capable to recognize more than 11 of the most common sheet metal structural features, and the procedure is fully automated. This provides remarkable savings in the production time, and protects against the human errors. This paper presents the developed system architecture, applied algorithms and system software implementation and testing.

Keywords: feature recognition, automation, sheet metal manufacturing, CAD, CAM

Procedia PDF Downloads 325

Authors: Mohamad Alnajem

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Purpose: To measure the readiness of the Kuwaiti small and medium sized manufacturing industries (K-SMMIs) to implement the lean system (LS) through an evaluation of their existing quality practices, and compare such readiness among different product sectors and ownership types. Design/methodology/approach: This study adopts the measurement framework developed by Al-Najem et al. (2013), which establishes six constructs related to lean quality practices, namely: process, planning and control, customer relations, suppliers relations, HR, and top management and leadership. Data were collected from a survey of 50 K-SMMIs operating in different industrial sectors. One research question and two hypotheses were developed and tested using t-test and Levene’s test, descriptive analysis, and one-way ANOVA. Findings: The results demonstrate that the K-SMMIs are far from being ready to implement lean. In addition, the study found that product sector and ownership type have no significant impact on the lean readiness in the K-SMMIs. Practical implications: This research provides insight into preparing Kuwaiti, and other SMMIs, to implement the LS by creating an assessment of their existing lean practices and readiness. Originality/value: This research is among a limited number of studies that have addressed lean within the Arab region, and only the second to examine the level of lean readiness of the K-SMMIs. It expands the literature on lean in developing countries, particularly in the Arab region, and can provide guidance to research within other countries in the region.

Keywords: Kuwaiti small and medium sized industries, lean system, lean readiness, manufacturing industries

Procedia PDF Downloads 172

Authors: Pisut Boonkaew, Jatuporn Thongsri

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In hard disk drive manufacturing industry, the process of reducing an unnecessary part and qualifying the quality of part before assembling is important. Thus, clamp was designed and fabricated as a fixture for holding in testing process. Basically, testing by trial and error consumes a long time to improve. Consequently, the simulation was brought to improve the part and reduce the time taken. The problem is the present clamp has a low life expectancy because of the critical stress that occurred. Hence, the simulation was brought to study the behavior of stress and compressive force to improve the clamp expectancy with all probability of designs which are present up to 27 designs, which excluding the repeated designs. The probability was calculated followed by the full fractional rules of six sigma methodology which was provided correctly. The six sigma methodology is a well-structured method for improving quality level by detecting and reducing the variability of the process. Therefore, the defective will be decreased while the process capability increasing. This research focuses on the methodology of stress and fatigue reduction while compressive force still remains in the acceptable range that has been set by the company. In the simulation, ANSYS simulates the 3D CAD with the same condition during the experiment. Then the force at each distance started from 0.01 to 0.1 mm will be recorded. The setting in ANSYS was verified by mesh convergence methodology and compared the percentage error with the experimental result; the error must not exceed the acceptable range. Therefore, the improved process focuses on degree, radius, and length that will reduce stress and still remain in the acceptable force number. Therefore, the fatigue analysis will be brought as the next process in order to guarantee that the lifetime will be extended by simulating through ANSYS simulation program. Not only to simulate it, but also to confirm the setting by comparing with the actual clamp in order to observe the different of fatigue between both designs. This brings the life time improvement up to 57% compared with the actual clamp in the manufacturing. This study provides a precise and trustable setting enough to be set as a reference methodology for the future design. Because of the combination and adaptation from the six sigma method, finite element, fatigue and linear regressive analysis that lead to accurate calculation, this project will able to save up to 60 million dollars annually.

Keywords: clamp, finite element analysis, structural, six sigma, linear regressive analysis, fatigue analysis, probability

Procedia PDF Downloads 211

Authors: Andreas Lind, Aitor Iriondo Pascual, Dan Hogberg, Lars Hanson

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Factory setup lifecycles are most often described and prepared in CAD environments; the preparation is based on experience and inputs from several cross-disciplinary processes. Early in the factory setup preparation, a so-called block layout is created. The intention is to describe a high-level view of the intended factory setup and to claim area reservations and allocations. Factory areas are then blocked, i.e., targeted to be used for specific intended resources and processes, later redefined with detailed factory setup layouts. Each detailed layout is based on the block layout and inputs from cross-disciplinary preparation processes, such as manufacturing sequence, productivity, workers’ workplace requirements, and resource setup preparation. However, this activity is often not carried out with all variables considered simultaneously, which might entail a risk of sub-optimizing the detailed layout based on manual decisions. Therefore, this work aims to realize a digital method for assembly manufacturing layout planning where productivity, area utilization, and ergonomics can be considered simultaneously in a cross-disciplinary manner. The purpose of the digital method is to support engineers in finding optimized designs of detailed layouts for assembly manufacturing factories, thereby facilitating better decisions regarding setups of future factories. Input datasets are company-specific descriptions of required dimensions for specific area reservations, such as defined dimensions of a worker’s workplace, material façades, aisles, and the sequence to realize the product assembly manufacturing process. To test and iteratively develop the digital method, a demonstrator has been developed with an adaptation of existing software that simulates and proposes optimized designs of detailed layouts. Since the method is to consider productivity, ergonomics, area utilization, and constraints from the automatically generated block layout, a multi-objective optimization approach is utilized. In the demonstrator, the input data are sent to the simulation software industrial path solutions (IPS). Based on the input and Lua scripts, the IPS software generates a block layout in compliance with the company’s defined dimensions of area reservations. Communication is then established between the IPS and the software EPP (Ergonomics in Productivity Platform), including intended resource descriptions, assembly manufacturing process, and manikin (digital human) resources. Using multi-objective optimization approaches, the EPP software then calculates layout proposals that are sent iteratively and simulated and rendered in IPS, following the rules and regulations defined in the block layout as well as productivity and ergonomics constraints and objectives. The software demonstrator is promising. The software can handle several parameters to optimize the detailed layout simultaneously and can put forward several proposals. It can optimize multiple parameters or weight the parameters to fine-tune the optimal result of the detailed layout. The intention of the demonstrator is to make the preparation between cross-disciplinary silos transparent and achieve a common preparation of the assembly manufacturing factory setup, thereby facilitating better decisions.

Keywords: factory setup, multi-objective, optimization, simulation

Procedia PDF Downloads 120

Authors: Guoliang Fan, Aiping Li, Xuemei Liu, Liyun Xu

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The performance of the tightening equipment will decline with the working process in manufacturing system. The main manifestations are the randomness and discretization degree increasing of the tightening performance. To evaluate the degradation tendency of the tightening performance accurately, a complexity measurement approach based on Kolmogorov entropy is presented. At first, the states of performance index are divided for calibrating the discrete degree. Then the complexity measurement model based on Kolmogorov entropy is built. The model describes the performance degradation tendency of tightening equipment quantitatively. At last, a study case is applied for verifying the efficiency and validity of the approach. The research achievement shows that the presented complexity measurement can effectively evaluate the degradation tendency of the tightening equipment. It can provide theoretical basis for preventive maintenance and life prediction of equipment.

Keywords: complexity measurement, Kolmogorov entropy, manufacturing system, performance evaluation, tightening equipment

Procedia PDF Downloads 236

Authors: Mohammad Syed Ali Molla, Mohammed Azim, Mohammad Esharuzzaman

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Centrifugal-casting machine is used in manufacturing special machine components like multi-layer journal bearing used in all internal combustion engine, steam, gas turbine and air craft turboengine where isotropic properties and high precisions are desired. Moreover, this machine can be used in manufacturing thin wall hightech machine components like cylinder liners and piston rings of IC engine and other machine parts like sleeves, and bushes. Heavy-duty machine component like railway wheel can also be prepared by centrifugal casting. A lot of technological developments are required in casting process for production of good casted machine body and machine parts. Usually defects like blowholes, surface roughness, chilled surface etc. are found in sand casted machine parts. But these can be removed by centrifugal casting machine using rotating metallic die. Moreover, die rotation, its temperature control, and good pouring practice can contribute to the quality of casting because of the fact that the soundness of a casting in large part depends upon how the metal enters into the mold or dies and solidifies. Poor pouring practice leads to variety of casting defects such as temperature loss, low quality casting, excessive turbulence, over pouring etc. Besides these, handling of molten metal is very unsecured and dangerous for the workers. In order to get rid of all these problems, the need of an automatic pouring device arises. In this research work, a robot assisted pouring device and a centrifugal casting machine are designed, developed constructed and tested experimentally which are found to work satisfactorily. The robot assisted pouring device is further modified and developed for using it in actual metal casting process. Lot of settings and tests are required to control the system and ultimately it can be used in automation of centrifugal casting machine to produce high-tech machine parts with desired precision.

Keywords: bearing, centrifugal casting, cylinder liners, robot

Procedia PDF Downloads 382

Authors: Alaa Alateeqi, Sara Aldhulaiee, Sara Alibraheem, Noura Alsaleh

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For the past few decades or so, Kuwait's local food industry has grown remarkably due to increase in demand for processed or semi processed food products in the market. It is important that the ever increasing food manufacturing/processing units maintain the required quality standards as per regional and to some extent international quality requirements. It has been realized that all Kuwait food manufacturing units should understand and follow the international standard practices, and moreover a set of guidelines must be set for quality assurance such that any new business in this area is aware of the minimum requirements. The current study has been undertaken to identify the gaps in Kuwait food industries in following the Good Manufacturing Practices (GMP) in terms of quality planning, control and quality assurance. GMP refers to Good Manufacturing Practices, which are a set of rules, laws or regulations that certify producing products within quality standards and ensuring that it is safe, pure and effective. The present study therefore reports about a ‘case study’ in a reputed food manufacturing unit in Kuwait; starting from assessment of the current practices followed by diagnosis, report of the diagnosis and road map and corrective measures for GMP implementation in the unit. The case study has also been able to identify the best practices and establish a benchmarking data for other companies to follow, through measuring the selected company's quality, policies, products and strategies and compare it with the established benchmarking data. A set of questionnaires and assessment mechanism has been established for companies to identify their ‘benchmarking score’ in relation to the number of non-conformities and conformities with the GMP standard requirements.

Keywords: good manufacturing practices, GMP, benchmarking, Kuwait Food Industries, food quality

Procedia PDF Downloads 440

Authors: Sungho Kim, Dae Shik Kim, Jong Min Lee

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Fluid catalytic cracking (FCC) process is one of the most important process in modern refinery indusrty. This paper focuses on the fluid catalytic cracking (FCC) process. As the FCC process is difficult to model well, due to its nonlinearities and various interactions between its process variables, rigorous process modeling of whole FCC plant is demanded for control and plant-wide optimization of the plant. In this study, a process design for the FCC plant includes riser reactor, main fractionator, and gas processing unit was developed. A reactor model was described based on four-lumped kinetic scheme. Main fractionator, gas processing unit and other process units are designed to simulate real plant data, using a process flowsheet simulator, Aspen PLUS. The custom reactor model was integrated with the process flowsheet simulator to develop an integrated process model.

Keywords: fluid catalytic cracking, simulation, plant data, process design

Procedia PDF Downloads 426

Authors: Talha Khan, Surendhar Kumaran, Rajeev Nair

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The development of economical, efficient, and reliable next-generation thermal and water management systems to provide efficient cooling and water management technologies is being pursued application in compact and lightweight spacecraft. The elimination of liquid-vapor phase change-based thermal and water management systems is being done due to issues with the reliability and robustness of this technology. To achieve the motive of implementing the principle of using an innovative evaporator and condenser design utilizing bimodal wicks manufactured using a microsecond pulsed CO₂ laser has been proposed in this study. Cylin drical, multilayered capillary copper wicks with a substrate diameter of 39 mm are additively manufactured using a pulsed laser. The copper particles used for layer-by-layer addition on the substrate measure in a diameter range of 225 to 450 micrometers. The primary objective is to develop a novel, high-quality, fast turnaround, laser-based additive manufacturing process that will eliminate the current technical challenges involved with the traditional manufacturing processes for nano/micro-sized powders, like particle agglomeration. Raster-scanned, pulsed-laser sintering process has been developed to manufacture 3D wicks with controlled porosity and permeability.

Keywords: liquid-vapor phase change, bimodal wicks, multilayered, capillary, raster-scanned, porosity, permeability

Procedia PDF Downloads 161

Authors: Onyedikachi Ulelu, Andrew P. Longstaff, Simon Fletcher, Simon Parkinson

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The widespread interest in 'Industry 4.0' or 'digital manufacturing' has led to significant research requiring the acquisition of data from sensors, instruments, and machine signals. In-depth research then identifies methods of analysis of the massive amounts of data generated before and during manufacture to solve a particular problem. The ultimate goal is for industrial Internet of Things (IIoT) data to be processed automatically to assist with either visualisation or autonomous system decision-making. However, the collection and processing of data in an industrial environment come with a cost. Little research has been undertaken on how to specify optimally what data to capture, transmit, process, and store at various levels of an edge-cloud network. The first step in this specification is to categorise IIoT data for efficient and effective use. This paper proposes the required attributes and classification to take manufacturing digital data from various sources to determine the most suitable location for data processing on the edge-cloud network. The proposed classification framework will minimise overhead in terms of network bandwidth/cost and processing time of machine tool data via efficient decision making on which dataset should be processed at the ‘edge’ and what to send to a remote server (cloud). A fast-and-frugal heuristic method is implemented for this decision-making. The framework is tested using case studies from industrial machine tools for machine productivity and maintenance.

Keywords: data classification, decision making, edge computing, industrial IoT, industry 4.0

Procedia PDF Downloads 149

Authors: Bing–Jing Zhao, Chang-Kui Liu, Hong Wang, Min Hu

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Electron beam rapid manufacturing (EBRM) or Selective laser melting is an additive manufacturing process that uses 3D CAD data as a digital information source and energy in the form of a high-power laser beam or electron beam to create three-dimensional metal parts by fusing fine metallic powders together.Object:The present study was conducted to evaluate the mechanical properties ,the phase transformation,the corrosivity and the biocompatibility of Ti-6Al-4V by EBRM,SLM and forging technique.Method: Ti-6Al-4V alloy standard test pieces were manufactured by EBRM, SLM and forging technique according to AMS4999,GB/T228 and ISO 10993.The mechanical properties were analyzed by universal test machine. The phase transformation was analyzed by X-ray diffraction and scanning electron microscopy. The corrosivity was analyzed by electrochemical method. The biocompatibility was analyzed by co-culturing with mesenchymal stem cell and analyzed by scanning electron microscopy (SEM) and alkaline phosphatase assay (ALP) to evaluate cell adhesion and differentiation, respectively. Results: The mechanical properties, the phase transformation, the corrosivity and the biocompatibility of Ti-6Al-4V by EBRM、SLM were similar to forging and meet the mechanical property requirements of AMS4999 standard. a­phase microstructure for the EBM production contrast to the a’­phase microstructure of the SLM product. Mesenchymal stem cell adhesion and differentiation were well. Conclusion: The property of the Ti-6Al-4V alloy manufactured by EBRM and SLM technique can meet the medical standard from this study. But some further study should be proceeded in order to applying well in clinical practice.

Keywords: 3D printing, Electron Beam Rapid Manufacturing (EBRM), Selective Laser Melting (SLM), Computer Aided Design (CAD)

Procedia PDF Downloads 431

Authors: Charles Chikwendu Okpala, Christopher Chukwutoo Ihueze

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As a technique that reduces variation in a product by lessening the sensitivity of the design to sources of variation, rather than by controlling their sources, Taguchi Robust Design entails the designing of ideal goods, by developing a product that has minimal variance in its characteristics and also meets the desired exact performance. This paper examined the concept of the manufacturing approach and its application to brake pad product of an automotive parts manufacturing company. Although the firm claimed that only defects, excess inventory, and over-production were the few wastes that grossly affect their productivity and profitability, a careful study and analysis of their manufacturing processes with the application of Single Minute Exchange of Dies (SMED) tool showed that the waste of waiting is the fourth waste that bedevils the firm. The selection of the Taguchi L9 orthogonal array which is based on the four parameters and the three levels of variation for each parameter revealed that with a range of 2.17, that waiting is the major waste that the company must reduce in order to continue to be viable. Also, to enhance the company’s throughput and profitability, the wastes of over-production, excess inventory, and defects with ranges of 2.01, 1.46, and 0.82, ranking second, third, and fourth respectively must also be reduced to the barest minimum. After proposing -33.84 as the highest optimum Signal-to-Noise ratio to be maintained for the waste of waiting, the paper advocated for the adoption of all the tools and techniques of Lean Production System (LPS), and Continuous Improvement (CI), and concluded by recommending SMED in order to drastically reduce set up time which leads to unnecessary waiting.

Keywords: lean production system, single minute exchange of dies, signal to noise ratio, Taguchi robust design, waste

Procedia PDF Downloads 99

Authors: Akshata S. Malani, Anagha D. Chaudhari, Rajeshkumar U. Sambhe

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Nanotechnology in pristine sense refers to building of structures at atomic and molecular scale. Meticulously nanotechnology encompasses the nanomaterials with atleast one dimension size ranging from 1 to 100 nanometres.Unlike the literal meaning of its name, nanotechnology is a massive concept beyond imagination. This paper predominantly deals with relevance of nanotechnology in automotive industries. New generation of automotives looks at nanotechnology as an emerging trend of manufacturing revolution. Intricate shapes can be made out of fairly inexpensive raw materials instead of conventional fabrication process. Though the current era have enough technology to face competition, nanotechnology can give futuristic implications to pick up the modern pace. Nanotechnology intends to bridge the gap between automotives with superior technical performance and their cost fluctuation. Preliminarily, it is an area of great scientific interest and a major shaper of many new technologies. Nanotechnology can be an ideal building block for automotive industries, under constant evolution offering a very wide scope of activity. It possesses huge potential and is still in the embryonic form of research and development.

Keywords: nanotechnology, nanomaterials, manufacturing, automotive industry

Procedia PDF Downloads 425

Authors: Ifeoma Patricia Osamor, Ayotunde Qudus Saka, Godwin Omoregbee, Hikmat Oreoluwalomo Omolaja

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Persistent fall in the value of Nigeria's currency compared to other foreign currencies, constant fluctuations in the exchange rate, and an increase in the price of goods and services necessitated the examination of the effects of exchange rate fluctuations on the economic performance of the manufacturing sector in Nigeria. An ex-post facto research design was adopted. Manufacturing gross domestic product (MGDP) was proxied for performance; Naira/Dollar exchange rate (NDE), Naira/Pounds exchange rate (NPE), Foreign exchange supply (FES) were used for exchange rate fluctuations; and inflation rate (INF) was a control variable. Data were collected from CBN Statistical Bulletin (2020) also World Development Indicators of the World Bank, while data collected were analysed using descriptive analysis, unit root, bounds cointegration test, and ARDL. Findings showed that changes in Naira/Dollar exchange rate (NDE) and Naira/Pound Sterling exchange rate negatively but significantly impact the economic performance of the manufacturing sector, while foreign exchange supply leads to an insignificant positive effect on the economic performance of the manufacturing. The study concludes that exchange rate fluctuations negatively impact the performance of the manufacturing sector in Nigeria and, therefore, recommends that government should encourage export diversification through agriculture, agro-investment, and agro-allied industries that would boost export in order to improve the value of the Naira, thereby stabilizing the exchange rate.

Keywords: exchange rate, economic performance, gross domestic product, inflation rate, foreign exchange supply

Procedia PDF Downloads 162

Authors: Darwin Junnior Sabino Diego, Brando Burgos Guerrero, Diego Arroyo Villanueva

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Additive manufacturing, commonly known as 3D printing, has revolutionized modern manufacturing by enabling the agile creation of complex objects. However, challenges persist in the consistency and quality of printed parts, particularly in their mechanical properties. This study focuses on addressing these challenges through the optimization of printing parameters in FDM technology, using Machine Learning techniques. Our aim is to improve the mechanical properties of printed objects by optimizing parameters such as speed, temperature, and orientation. We implement a methodology that combines experimental data collection with Machine Learning algorithms to identify relationships between printing parameters and mechanical properties. The results demonstrate the potential of this methodology to enhance the quality and consistency of 3D printed products, with significant applications across various industrial fields. This research not only advances understanding of additive manufacturing but also opens new avenues for practical implementation in industrial settings.

Keywords: 3D printing, additive manufacturing, machine learning, mechanical properties

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Authors: Paua Ketan, Bhagate Rajkumar, Adiga Ganesh, M. Kiran

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Low gear noise is an important sound quality feature in modern passenger cars. Annoying gear noise from the gearbox is influenced by the gear design, gearbox shaft layout, manufacturing deviations in the components, assembly errors and the mounting arrangement of the complete gearbox. Geometrical deviations in the form of profile and lead errors are often present on the flanks of the inspected gears. Ghost frequencies of a gear are very challenging to identify in standard gear measurement and analysis process due to small wavelengths involved. In this paper, gear whine noise occurring at non-integral multiples of gear mesh frequency of passenger car gearbox is investigated and the root cause is identified using the displacement deviation analysis (DDA) method. DDA method is applied to identify ghost frequency excitations on the flanks of gears arising out of generation grinding. Frequency identified through DDA correlated with the frequency of vibration and noise on the end-of-line machine as well as vehicle level measurements. With the application of DDA method along with standard lead profile measurement, gears with ghost frequency geometry deviations were identified on the production line to eliminate defective parts and thereby eliminate ghost frequency noise from a vehicle. Further, displacement deviation analysis can be used in conjunction with the manufacturing process simulation to arrive at suitable countermeasures for arresting the ghost frequency.

Keywords: displacement deviation analysis, gear whine, ghost frequency, sound quality

Procedia PDF Downloads 109

Authors: Fernanda A. P. Peres, Thiago N. Peres, Flavio S. Fogliatto, Michel J. Anzanello

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Batch processes are widely used in food industry and have an important role in the production of high added value products, such as chocolate. Process performance is usually described by variables that are monitored as the batch progresses. Data arising from these processes are likely to display a strong correlation-autocorrelation structure, and are usually monitored using control charts based on multiway principal components analysis (MPCA). Process control of a new batch is carried out comparing the trajectories of its relevant process variables with those in a reference set of batches that yielded products within specifications; it is clear that proper determination of the reference set is key for the success of a correct signalization of non-conforming batches in such quality control schemes. In chocolate manufacturing, misclassifications of non-conforming batches in the conching phase may lead to significant financial losses. In such context, the accuracy of process control grows in relevance. In addition to that, the main assumption in MPCA-based monitoring strategies is that all batches are synchronized in duration, both the new batch being monitored and those in the reference set. Such assumption is often not satisfied in chocolate manufacturing process. As a consequence, traditional techniques as MPCA-based charts are not suitable for process control and monitoring. To address that issue, the objective of this work is to compare the performance of three dynamic time warping (DTW) methods in the alignment and synchronization of chocolate conching process variables’ trajectories, aimed at properly determining the reference distribution for multivariate statistical process control. The power of classification of batches in two categories (conforming and non-conforming) was evaluated using the k-nearest neighbor (KNN) algorithm. Real data from a milk chocolate conching process was collected and the following variables were monitored over time: frequency of soybean lecithin dosage, rotation speed of the shovels, current of the main motor of the conche, and chocolate temperature. A set of 62 batches with durations between 495 and 1,170 minutes was considered; 53% of the batches were known to be conforming based on lab test results and experts’ evaluations. Results showed that all three DTW methods tested were able to align and synchronize the conching dataset. However, synchronized datasets obtained from these methods performed differently when inputted in the KNN classification algorithm. Kassidas, MacGregor and Taylor’s (named KMT) method was deemed the best DTW method for aligning and synchronizing a milk chocolate conching dataset, presenting 93.7% accuracy, 97.2% sensitivity and 90.3% specificity in batch classification, being considered the best option to determine the reference set for the milk chocolate dataset. Such method was recommended due to the lowest number of iterations required to achieve convergence and highest average accuracy in the testing portion using the KNN classification technique.

Keywords: batch process monitoring, chocolate conching, dynamic time warping, reference set distribution, variable duration

Procedia PDF Downloads 140

Authors: Romi Dey

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Introduction: One of the most important criteria for technology to sustain and grow is through it’s elaborate and intuitive design methodology and design thinking. Designing for enterprise applications that cater to Just in Time Technology is one of the most challenging and detailed processes any User Experience Designer would come across. Description: The basic principles of Design, when applied to tailor to these technologies, creates an immense challenge and that’s how a set of redefined and revised design principles that can be applied to designing any Just In Time manufacturing solution. Findings: The thorough process of understanding the end user, their existing pain points which they’ve faced in the real world, their responsibilities and expectations, the core needs and last but not the least the demands, creates havoc nurturing of the design methodologies for the Just in Time solutions. With respect to the business aspect, design and design principles play a strong role in any form of innovation. Conclusion: Innovation and knowledge about the latest technologies are the keywords in the manufacturing industry. It becomes crucial for the product development team to be precise in their understanding of the technology and being sure of end users expectation.

Keywords: design thinking, enterprise application, Just in Time, user experience design

Procedia PDF Downloads 135

Authors: Yusri Yusof, Kamran Latif

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Computer Numeric Control (CNC) machine has been widely used in the industries since its inception. Currently, in CNC technology has been used for various operations like milling, drilling, packing and welding etc. with the rapid growth in the manufacturing world the demand of flexibility in the CNC machines has rapidly increased. Previously, the commercial CNC failed to provide flexibility because its structure was of closed nature that does not provide access to the inner features of CNC. Also CNC’s operating ISO data interface model was found to be limited. Therefore, to overcome that problem, Open Architecture Control (OAC) technology and STEP-NC data interface model are introduced. At present the Personal Computer (PC) has been the best platform for the development of open-CNC systems. In this paper, both ISO data interface model interpretation, its verification and execution has been highlighted with the introduction of the new techniques. The proposed is composed of ISO data interpretation, 3D simulation and machine motion control modules. The system is tested on an old 3 axis CNC milling machine. The results are found to be satisfactory in performance. This implementation has successfully enabled sustainable manufacturing environment.

Keywords: CNC, ISO 6983, ISO 14649, LabVIEW, open architecture control, reconfigurable manufacturing systems, sustainable manufacturing, Soft-CNC

Procedia PDF Downloads 482

Authors: Ashiff Khan, A. Seetharaman, Abhijit Dasgupta

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The new era of big data (BD) is influencing chemical industries tremendously, providing several opportunities to reshape the way they operate and help them shift towards intelligent manufacturing. Given the availability of free software and the large amount of real-time data generated and stored in process plants, chemical industries are still in the early stages of big data adoption. The industry is just starting to realize the importance of the large amount of data it owns to make the right decisions and support its strategies. This article explores the importance of professional competencies and data science that influence BD in chemical industries to help it move towards intelligent manufacturing fast and reliable. This article utilizes a literature review and identifies potential applications in the chemical industry to move from conventional methods to a data-driven approach. The scope of this document is limited to the adoption of BD in chemical industries and the variables identified in this article. To achieve this objective, government, academia, and industry must work together to overcome all present and future challenges.

Keywords: chemical engineering, big data analytics, industrial revolution, professional competence, data science

Procedia PDF Downloads 54

Authors: Eng Toon Saw, Kun Liang Ang, Wei He, Xuecheng Dong, Seeram Ramakrishna

Abstract:

Solvent recovery process is receiving utmost attention in recent year due to the scarcity of natural resource and consciousness of circular economy in chemical and pharmaceutical manufacturing process. Solvent dehydration process is one of the important process to recover and to purify the solvent for reuse. Due to the complexity of solvent waste or wastewater effluent produced in pharmaceutical industry resulting the wastewater treatment process become complicated, thus an alternative solution is to recover the valuable solvent in solvent waste. To treat solvent waste and to upgrade solvent purity, membrane pervaporation process is shown to be a promising technology due to the energy intensive and low footprint advantages. Ceramic membrane is adopted as solvent dehydration membrane owing to the chemical and thermal stability properties as compared to polymeric membrane. NaA zeolite membrane is generally used as solvent dehydration process because of its narrow and distinct pore size and high hydrophilicity. NaA zeolite membrane has been mainly applied in alcohol dehydration in fermentation process. At this stage, the membrane performance exhibits high separation factor with low flux using tubular ceramic membrane. Thus, defect free and ultrathin NaA membrane should be developed to increase water flux. Herein, we report a simple preparation protocol to prepare ultrathin NaA zeolite membrane supported on tubular ceramic membrane by controlling the seed size synthesis, seeding methods and conditions, ceramic substrate surface pore size selection and secondary growth conditions. The microstructure and morphology of NaA zeolite membrane will be examined and reported. Moreover, the membrane separation performance and stability will also be reported in isopropanol dehydration, ketone dehydration and ester dehydration particularly for the application in pharmaceutical industry.

Keywords: ceramic membrane, NaA zeolite, pharmaceutical industry, solvent recovery

Procedia PDF Downloads 209

Authors: Nivatha Elangovan, Lakshman Neelakantan, Murugaiyan Amirthalingam

Abstract:

Magnesium and its alloys are widely used for various lightweight engineering and biomedical applications as they render high strength to low weight ratio and excellent corrosion resistance. These alloys possess good bio-compatibility and similar mechanical properties to natural bone. However, manufacturing magnesium alloy components by conventional formative and subtractive methods is challenging due to their poor castability, oxidation potential, and machinability. Therefore, efforts are made to produce complex-design containing magnesium alloy components by additive manufacturing (AM). Arc-wire directed energy deposition (AW-DED), also known as wire arc additive manufacturing (WAAM), is more attractive to produce large volume components with increased productivity than any other AM technique. In this research work, efforts were made to optimise the deposition parameters to build thick-walled (about 10 mm) AZ31 magnesium alloy components by a gas metal arc (GMA) based AW-DED process. By using controlled dip short-circuiting metal transfer in a GMA process, depositions were carried out without defects and spatter formation. Current and voltage waveforms were suitably modified to achieve stable metal transfer. Moreover, the droplet transfer behaviour was analysed using high-speed image analysis and correlated with arc energy. Optical and scanning electron microscopy analyses were carried out to correlate the influence of deposition parameters with the microstructural evolution during deposition. The investigation reveals that by carefully controlling the current-voltage waveform and droplet transfer behaviour, it is possible to stabilise equiaxed grain microstructures in the deposited AZ31 components. The printed component exhibited an improved mechanical property as equiaxed grains improve the ductility and enhance the toughness. The equiaxed grains in the component improved the corrosion-resistant behaviour of other conventionally manufactured components.

Keywords: arc wire directed energy deposition, AZ31 magnesium alloy, equiaxed grain, corrosion

Procedia PDF Downloads 89

Authors: Rajkishore Nayak, Tarun Panwar, Majo George

Abstract:

The study focuses on investigating the factors that influence the growth of fashion and textile manufacturing in the Sub-Saharan Africa (SSA) countries. This paper endeavours to identify, analyse and evaluate the critical factors associated with the growth of fashion and textile manufacturing in SSA countries. This research has done a Strength, Weakness, Opportunity, and Threat (SWOT) analysis based on the available literature and the knowledge of authors in garment manufacturing and export. It was found that the SSA countries have shown little growth in fashion and textile manufacturing and export from the starting of the year 2000. Unlike the developing countries such as Vietnam and Bangladesh, the total export to the US, the EU and other parts of the world has declined. On the other hand, the total supply of fashion and textiles to the domestic market has been in rise. However, the local communities still need to rely on other countries to meet their demand. Availability of cheaper imported clothes from other countries such as Bangladesh, China and Vietnam have made it difficult for the local manufacturers to produce at a cheaper price.

Keywords: Sub-Saharan Africa, developing countries, apparel industry, fashion and textile, sustainable fashion

Procedia PDF Downloads 96

Authors: Khaled Al-Badani, Andrew Norbury, Essam Elmshawet, Glynn Rotwell, Ian Jenkinson , James Ren

Abstract:

Micro welding procedures are widely used for joining materials, developing duplex components or functional surfaces, through various methods such as Micro Discharge Welding or Spot Welding process, which can be found in the engineering, aerospace, automotive, biochemical, biomedical and numerous other industries. The relationship between the material properties, structure and processing is very important to improve the structural integrity and the final performance of the welded joints. This includes controlling the shape and the size of the welding nugget, state of the heat affected zone, residual stress, etc. Nowadays, modern high volume productions require the welding of much versatile shapes/sizes and material systems that are suitable for various applications. Hence, an improved understanding of the micro welding process and the digital tools, which are based on computational numerical modelling linking key welding parameters, dimensional attributes and functional performance of the weldment, would directly benefit the industry in developing products that meet current and future market demands. This paper will introduce recent work on developing an integrated experimental and numerical modelling code for micro welding techniques. This includes similar and dissimilar materials for both ferrous and non-ferrous metals, at different scales. The paper will also produce a comparative study, concerning the differences between the micro discharge welding process and the spot welding technique, in regards to the size effect of the welding zone and the changes in the material structure. Numerical modelling method for the micro welding processes and its effects on the material properties, during melting and cooling progression at different scales, will also be presented. Finally, the applications of the integrated numerical modelling and the material development for the digital manufacturing of welding, is discussed with references to typical application cases such as sensors (thermocouples), energy (heat exchanger) and automotive structures (duplex steel structures).

Keywords: computer modelling, droplet formation, material distortion, materials forming, welding

Procedia PDF Downloads 233

Authors: M. Regis, E. Marin, S. Fusi, M. Pressacco, L. Fedrizzi

Abstract:

Electron Beam Melting (EBM) process was used to prepare porous scaffolds with controlled porosity to ensure optimal levels of osteointegration for different trabeculae sizes. Morphological characterization by means of SEM analyses was carried out to assess pore dimensions; tensile, compression and adhesion tests have been carried out to determine the mechanical behavior. The results indicate that EBM process allows the creation of regular and repeatable porous scaffolds. Mechanical properties greatly depend on pore dimension and on bulk-pore ratio. Adhesion resistance meets the normative requirements, and the overall performance of the produced structures is compatible with potential orthopaedic applications.

Keywords: additive manufacturing, orthopaedic implants, osteointegration, trabecular structures

Procedia PDF Downloads 292

Authors: Rakan A. Ahmed, Raja S. Khan, Mohammed M. Qahtani

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This paper explores the transformative impact of laser cladding technology on the circular economy, emphasizing its role in reducing environmental impact compared to traditional welding methods. Laser cladding, an innovative manufacturing process, optimizes resource efficiency and sustainability by significantly decreasing power consumption and minimizing material waste. The study explores how laser cladding operates within the framework of the circular economy, promoting energy efficiency, waste reduction, and emissions control. Through a comparative analysis of energy and material consumption between laser cladding and conventional welding methods, the paper highlights the significant strides in environmental conservation and resource optimization made possible by laser cladding. The findings highlight the potential for this technology to revolutionize industrial practices and propel a more sustainable and eco-friendly manufacturing landscape.

Keywords: laser cladding, circular economy, carbon emission, energy

Procedia PDF Downloads 47

Authors: Suresh Vanguri, Suresh Palla, Prasad G., Ramaswamy V., Kalyani K. V., Chaturvedi S. K., Mohapatra B. N., Sunder Rao TBVN

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The utilization of industrial waste materials and by-products in the cement industry helps in the conservation of natural resources besides avoiding the problems arising due to waste dumping. The use of non-carbonated materials as raw mix components in clinker manufacturing is identified as one of the key areas to reduce Green House Gas (GHG) emissions. Chrome sludge is a waste material generated from the manufacturing process of sodium dichromate. This paper aims to present studies on the use of chrome sludge in clinker manufacturing, its impact on the development of clinker mineral phases and on the cement properties. Chrome sludge was found to contain substantial amounts of CaO, Fe2O3 and Al2O3 and therefore was used to replace some conventional sources of alumina and iron in the raw mix. Different mixes were prepared by varying the chrome sludge content from 0 to 5 % and the mixes were evaluated for burnability. Laboratory prepared clinker samples were evaluated for qualitative and quantitative mineralogy using X-ray Diffraction Studies (XRD). Optical microscopy was employed to study the distribution of clinker phases, their granulometry and mineralogy. Since chrome sludge also contains considerable amounts of chromium, studies were conducted on the leachability of heavy elements in the chrome sludge as well as in the resultant cement samples. Estimation of heavy elements, including chromium was carried out using ICP-OES. Further, the state of chromium valence, Cr (III) & Cr (VI), was studied using conventional chemical analysis methods coupled with UV-VIS spectroscopy. Assimilation of chromium in the clinker phases was investigated using SEM-EDXA studies. Bulk cement was prepared from the clinker to study the effect of chromium sludge on the cement properties such as setting time, soundness, strength development against the control cement. Studies indicated that chrome sludge can be successfully utilized and its content needs to be optimized based on raw material characteristics.

Keywords: chrome sludge, leaching, mineralogy, non-carbonate materials

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Authors: Nadia Fatima Zahra Malki

Abstract:

The aim of the study is to show the role of total Quality Management on firm performance, research relied on the views of a sample managers working in the Marinel pharmaceutical company. The research aims to achieve many objectives, including increasing awareness of the concepts of Total Quality Management on Firm Performance, especially in the manufacturing firm, providing a future vision of the possibility of success, and the actual application of the Principles of Total Quality Management in the manufacturing company. The research adopted a default model was built after a review and analysis of the literature review in the context of one hypothesis's main points at the origin of a group of sub-hypotheses. The research presented a set of conclusions, and the most important of these conclusions was that there is a relationship between the Principles of TQM and Firm Performance.

Keywords: total quality management, competitive advantage, companies, objectives

Procedia PDF Downloads 14