Search results for: Flexible Manufacturing System

Authors: Q. Z. Yang, B. H. Chua, B. Song

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Technology assessment is a vital part of decision process in manufacturing, particularly for decisions on selection of new sustainable manufacturing processes. To assess these processes, a matrix approach is introduced and sustainability assessment models are developed. Case studies show that the matrix-based approach provides a flexible and practical way for sustainability evaluation of new manufacturing technologies such as those used in surface coating. The technology assessment of coating processes reveals that compared with powder coating, the sol-gel coating can deliver better technical, economical and environmental sustainability with respect to the selected sustainability evaluation criteria for a decorative coating application of car wheels.

Keywords: Evaluation matrix, sustainable manufacturing, surface coating, technology assessment

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Authors: Qian Wang, Sylvain Lassalle, Antony R. Mileham, Geraint W. Owen

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This paper mathematically analyses the varying magnitude of production loss, which may occur due to idle time (inprocess waiting time and traveling time) on a linear walking worker assembly line. Within this flexible and reconfigurable assembly system, each worker travels down the line carrying out each assembly task at each station; and each worker accomplishes the assembly of a unit from start to finish and then travels back to the first station to start the assembly of a new product. This strategy of system design attempts to combine the flexibility of the U-shaped moving worker assembly cell with the efficiency of the conventional fixed worker assembly line. The paper aims to evaluate the effect of idle time that may offset the labor efficiency of each walking worker providing an insight into the mechanism of such a flexible and reconfigurable assembly system.

Keywords: Production lines, manufacturing systems, assemblysystems, walking workers.

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Authors: Hendry Muljadi, Hideaki Takeda, Koichi Ando

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A manufacturing feature can be defined simply as a geometric shape and its manufacturing information to create the shape. In a feature-based process planning system, feature library plays an important role in the extraction of manufacturing features with their proper manufacturing information. However, to manage the manufacturing information flexibly, it is important to build a feature library that is easy to modify. In this paper, a Wiki-based feature library is proposed.

Keywords: Manufacturing feature, feature library, feature ontology, process planning, Wiki, MediaWiki.

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Authors: So Jeong Nam, Seung Woo Lee, Jai-Kyung Lee

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With the globalized production and logistics environment, the need for reducing the product development interval and lead time, having a faster response to orders, conforming to quality standards, fair tracking, and boosting information exchanging activities with customers and partners, and coping with changes in the management environment, manufacturers are in dire need of an information management system in their manufacturing environments. There are lots of information systems that have been designed to manage the condition or operation of equipment in the field but existing systems have a decentralized architecture, which is not unified. Also, these systems cannot effectively handle the status data extraction process upon encountering a problem related to protocols or changes in the equipment or the setting. In this regard, this paper will introduce a system for processing and saving the status info of production equipment, which uses standard representation formats, to enable flexible responses to and support for variables in the field equipment. This system can be used for a variety of manufacturing and equipment settings and is capable of interacting with higher-tier systems such as MES.

Keywords: DAS, Equipment Status, Regular Expression

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Authors: S. Ariffin, K. Hasnan, R.H. Weston

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A new generation of manufacturing machines so-called MIMCA (modular and integrated machine control architecture) capable of handling much increased complexity in manufacturing control-systems is presented. Requirement for more flexible and effective control systems for manufacturing machine systems is investigated and dimensioned-which highlights a need for improved means of coordinating and monitoring production machinery and equipment used to- transport material. The MIMCA supports simulation based on machine modeling, was conceived by the authors to address the issues. Essentially MIMCA comprises an organized unification of selected architectural frameworks and modeling methods, which include: NISTRCS, UMC and Colored Timed Petri nets (CTPN). The unification has been achieved; to support the design and construction of hierarchical and distributed machine control which realized the concurrent operation of reusable and distributed machine control components; ability to handle growing complexity; and support requirements for real- time control systems. Thus MIMCA enables mapping between 'what a machine should do' and 'how the machine does it' in a well-defined but flexible way designed to facilitate reconfiguration of machine systems.

Keywords: Machine control, architectures, Petri nets, modularity, modeling, simulation.

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Authors: Wan Hasrulnizzam Wan Mahmood, Mohd Nizam Ab Rahman, Baba Md Deros

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Green supply chain management is an increasingly recognized practice among companies that are seeking to improve environmental performance. Of particular concern is how to arouse organizational awareness and put green activities into practice in order to enhance manufacturing performances. This paper investigates the correlation of green supply chain practices and manufacturing performances in Malaysian certified MS ISO 14000 manufacturing firms. The findings shows that green supply chain practices which that can be denominated product recycling, environmental compliance and optimization have significant influence to some of the manufacturing performances.

Keywords: Green supply chain practice, Manufacturing system performance, Malaysia

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Authors: Naveen Virmani, Rajeev Saha, Rajeshwar Sahai

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Leagile is combination of both lean and agile system. Lean is concerned with less of everything i.e. less material, less time, less space, less manpower to produce a product, while agile is concerned with quick respond to customer demand and to reconfigure the system as soon as possible to meet the customer expectations well on time. The market is excessively competitive, so there is a dire need for the companies to adopt new and modern technologies with latest equipments. It has been seen that implementation of leagile system become tedious so the purpose of the paper is to find critical success factors (CSF) affecting leagile manufacturing system using literature review and rank them by using modified TOPSIS (Technique of order preference by similarity to ideal solution) technique.

Keywords: Agile manufacturing, lean manufacturing, leagile manufacturing, modified TOPSIS.

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Authors: Rudi Kurniawan Arief

Abstract:

Manufacturing cost and setup time are the hot topics to improve in Metal Stamping industry because material and components price are always rising up while costumer requires to cut down the component price year by year. The Single Minute Exchange of Die (SMED) is one of many methods to reduce waste in stamping industry. The Japanese Quick Die Change (QDC) dies system is one of SMED systems that could reduce both of setup time and manufacturing cost. However, this system is rarely used in stamping industries. This paper will analyze how deep the QDC dies system could reduce setup time and the manufacturing cost. The research is conducted by direct observation, simulating and comparing of QDC dies system with conventional dies system. In this research, we found that the QDC dies system could save up to 35% of manufacturing cost and reduce 70% of setup times. This simulation proved that the QDC die system is effective for cost reduction but must be applied in several parallel production processes.

Keywords: Press die, metal stamping, quick die change, QDC system, single minute exchange die, manufacturing cost saving, SMED.

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Authors: M. H. M. Rusli, A. Jaffar, M. T. Ali, S. Muhamud @ Kayat

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Lean manufacturing is a production philosophy made popular by Toyota Motor Corporation (TMC). It is globally known as the Toyota Production System (TPS) and has the ultimate aim of reducing cost by thoroughly eliminating wastes or muda. TPS embraces the Just-in-time (JIT) manufacturing; achieving cost reduction through lead time reduction. JIT manufacturing can be achieved by implementing Pull system in the production. Furthermore, TPS aims to improve productivity and creating continuous flow in the production by arranging the machines and processes in cellular configurations. This is called as Cellular Manufacturing Systems (CMS). This paper studies on integrating the CMS with the Pull system to establish a Big Island-Pull system production for High Mix Low Volume (HMLV) products in an automotive component industry. The paper will use the build-in JIT system steps adapted from TMC to create the Pull system production and also create a shojinka line which, according to takt time, has the flexibility to adapt to demand changes simply by adding and taking out manpower. This will lead to optimization in production.

Keywords: Big Island layout, Lean manufacturing, Material and Information Flow Chart, Pull system production, TPS.

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Authors: Liubov A. Magerramova, Mikhail A. Petrov, Vladimir V. Isakov, Liana A. Shcherbinina, Suren G. Gukasyan, Daniil V. Povalyukhin, Olga G. Klimova-Korsmik, Darya V. Volosevich

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Aircraft engines are developing along the path of increasing resource, strength, reliability, and safety. The building of gas turbine engine body parts is a complex design and technological task. Particularly complex in the design and manufacturing are the casings of the input stages of helicopter gearboxes and central drives of aircraft engines. Traditional technologies, such as precision casting or isothermal forging, are characterized by significant limitations in parts production. For parts like housing, additive technologies guarantee spatial freedom and limitless or flexible design. This article presents the results of computational and experimental studies. These investigations justify the applicability of additive technologies (AT) to reduce the weight of aircraft housing gearbox parts by up to 32%. This is possible due to geometrical optimization compared to the classical, less flexible manufacturing methods and as-casted aircraft parts with over-insured values of safety factors. Using an example of the body of the input stage of an aircraft gearbox, visualization of the layer-by-layer manufacturing of a part based on thermal deformation was demonstrated.

Keywords: Additive technologies, gas turbine engines, geometric optimization, weight reduction.

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Authors: Jung-Chuan Chou, Wei-Chuan Chen, Chien-Cheng Chen

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This study is concerned with pH solution detection using 2 × 4 flexible sensor array based on a plastic polyethylene terephthalate (PET) substrate that is coated a conductive layer and a ruthenium dioxide (RuO2) sensitive membrane with the technologies of screen-printing and RF sputtering. For data analysis, we also prepared a dynamic measurement system for acquiring the response voltage and analyzing the characteristics of the working electrodes (WEs), such as sensitivity and linearity. In this condition, an array measurement system was designed to acquire the original signal from sensor array, and it is based on the method of digital signal processing (DSP). The DSP modifies the unstable acquisition data to a direct current (DC) output using the technique of digital filter. Hence, this sensor array can obtain a satisfactory yield, 62.5%, through the design measurement and analysis system in our laboratory.

Keywords: Flexible sensor array, PET, RuO2, dynamic measurement, data analysis.

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Authors: Hendry Muljadi, Hideaki Takeda, Koichi Ando

Abstract:

A manufacturing feature can be defined simply as a geometric shape and its manufacturing information to create the shape. In a feature-based process planning system, feature library that consists of pre-defined manufacturing features and the manufacturing information to create the shape of the features, plays an important role in the extraction of manufacturing features with their proper manufacturing information. However, to manage the manufacturing information flexibly, it is important to build a feature library that can be easily modified. In this paper, the implementation of Semantic Wiki for the development of the feature library is proposed.

Keywords: Manufacturing feature, feature library, feature ontology, process planning, Wiki, MediaWiki, Semantic Wiki.

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Authors: F. Hosseinpour, H. Hajihosseini

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Simulation is a very helpful and valuable work tool in manufacturing. It can be used in industrial field allowing the system`s behavior to be learnt and tested. Simulation provides a low cost, secure and fast analysis tool. It also provides benefits, which can be reached with many different system configurations. Topics to be discussed include: Applications, Modeling, Validating, Software and benefits of simulation. This paper provides a comprehensive literature review on research efforts in simulation.

Keywords: Manufacturing, modeling, simulation, training.

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Authors: Sophia Fry, Mahir Irtiza, Alexa Hoffman, Yousef Sardahi

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This study presents an intelligent control algorithm for a flexible robotic arm. Fuzzy control is used to control the motion of the arm to maintain the arm tip at the desired position while reducing vibration and increasing the system speed of response. The Fuzzy controller (FC) is based on adding the tip angular position to the arm deflection angle and using their sum as a feedback signal to the control algorithm. This reduces the complexity of the FC in terms of the input variables, number of membership functions, fuzzy rules, and control structure. Also, the design of the fuzzy controller is model-free and uses only our knowledge about the system. To show the efficacy of the FC, the control algorithm is implemented on the flexible joint manipulator (FJM) developed by Quanser. The results show that the proposed control method is effective in terms of response time, overshoot, and vibration amplitude.

Keywords: Fuzzy logic control, model-free control, flexible joint manipulators, nonlinear control.

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Authors: M. Holle, M. Roth, M. R. Gürtler, U. Lindemann

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This paper gives insights into the research project “InnoCyFer” (in the form of an outlook) which is funded by the German Federal Ministry of Economics and Technology. Enabling the integrated customer individual product design as well as flexible manufacturing of these products are the main objectives of the project. To achieve this, a web-based Open Innovation-Platform containing an integrated Toolkit will be developed. This toolkit enables the active integration of the customer’s creativity and potentials of innovation in the product development process. Furthermore, the project will show the chances and possibilities of customer individualized products by building and examining the continuous process from innovation through the customers to the flexible manufacturing of individual products.

Keywords: Customer Individual Product Design, Innovation Networks, Open Innovation, Open Innovation Platform and Toolkit.

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Authors: Muhammad Marsudi, Dzuraidah Abdul Wahab, Che Hassan Che Haron

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Modeling of a manufacturing system enables one to identify the effects of key design parameters on the system performance and as a result to make correct decision. This paper proposes a manufacturing system modeling approach using a spreadsheet model based on queuing network theory, in which a static capacity planning model and stochastic queuing model are integrated. The model was used to improve the existing system utilization in relation to product design. The model incorporates few parameters such as utilization, cycle time, throughput, and batch size. The study also showed that the validity of developed model is good enough to apply and the maximum value of relative error is 10%, far below the limit value 32%. Therefore, the model developed in this study is a valuable alternative model in evaluating a manufacturing system

Keywords: Manufacturing system, product design, spreadsheet model, utilization.

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Authors: H.-H. Doh, J.-M. Yu, Y.-J. Kwon, J.-H. Shin, H.-W. Kim, S.-H. Nam, D.-H. Lee

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This paper suggests a decision tree based approach for flexible job shop scheduling with multiple process plans, i.e. each job can be processed through alternative operations, each of which can be processed on alternative machines. The main decision variables are: (a) selecting operation/machine pair; and (b) sequencing the jobs assigned to each machine. As an extension of the priority scheduling approach that selects the best priority rule combination after many simulation runs, this study suggests a decision tree based approach in which a decision tree is used to select a priority rule combination adequate for a specific system state and hence the burdens required for developing simulation models and carrying out simulation runs can be eliminated. The decision tree based scheduling approach consists of construction and scheduling modules. In the construction module, a decision tree is constructed using a four-stage algorithm, and in the scheduling module, a priority rule combination is selected using the decision tree. To show the performance of the decision tree based approach suggested in this study, a case study was done on a flexible job shop with reconfigurable manufacturing cells and a conventional job shop, and the results are reported by comparing it with individual priority rule combinations for the objectives of minimizing total flow time and total tardiness.

Keywords: Flexible job shop scheduling, Decision tree, Priority rules, Case study.

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Authors: Amer S. Al-Yahmadi, T.C. Hsia

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This paper seeks to develop simple yet practical and efficient control scheme that enables cooperating arms to handle a flexible beam. Specifically the problem studied herein is that of two arms rigidly grasping a flexible beam and such capable of generating forces/moments in such away as to move a flexible beam along a predefined trajectory. The paper develops a sliding mode control law that provides robustness against model imperfection and uncertainty. It also provides an implicit stability proof. Simulation results for two three joint arms moving a flexible beam, are presented to validate the theoretical results.

Keywords: Sliding mode control, cooperative manipulators.

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Authors: Sergey M. Karabanov, Dmitry V. Suvorov, Dmitry Yu. Tarabrin

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The operating principle of magnetically controlled microelectromechanical system (MEMS) switches is based on controlling the beam movement under the influence of a magnetic field. Currently, there is a MEMS switch design with a flexible ferromagnetic electrode in the form of a fixed-terminal beam, with an electrode fastened on a straight or cranked anchor. The basic performance characteristics of magnetically controlled MEMS switches (service life, sensitivity, contact resistance, fast response) are largely determined by the flexible electrode design. To ensure the stable and controlled motion of the flexible electrode, it is necessary to provide the optimal design of a flexible electrode.

Keywords: MEMS switch, magnetic sensitivity, magnetic concentrator.

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Authors: E. Abedi, A. Ahmadi Nadooshan, S. Salehi

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Modeling and vibration of a flexible link manipulator with tow flexible links and rigid joints are investigated which can include an arbitrary number of flexible links. Hamilton principle and finite element approach is proposed to model the dynamics of flexible manipulators. The links are assumed to be deflection due to bending. The association between elastic displacements of links is investigated, took into account the coupling effects of elastic motion and rigid motion. Flexible links are treated as Euler-Bernoulli beams and the shear deformation is thus abandoned. The dynamic behavior due to flexibility of links is well demonstrated through numerical simulation. The rigid-body motion and elastic deformations are separated by linearizing the equations of motion around the rigid body reference path. Simulation results are shown on for both position and force trajectory tracking tasks in the presence of varying parameters and unknown dynamics remarkably well. The proposed method can be used in both dynamic simulation and controller design.

Keywords: Flexible manipulator, flexible link, dynamicmodeling, end point.

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Authors: Prabhakar Sathujoda

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Vibration analysis of a misaligned rotor coupling bearing system has been carried out while decelerating through its critical speed. The finite element method (FEM) is used to model the rotor system and simulate flexural vibrations. A flexible coupling with a frictionless joint is considered in the present work. The continuous wavelet transform is used to extract the misalignment features from the simulated time response. Subcritical speeds at one-half, one-third, and one-fourth the critical speed have appeared in the wavelet transformed vibration response of a misaligned rotor coupling bearing system. These features are also verified through a parametric study.

Keywords: Continuous wavelet transform, flexible coupling, rotor system, sub critical speed.

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Authors: Rajab Abdullah Hokoma

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Manufacturing, production and service industries within Libya have struggled with many problems during the past two decades due to many difficulties. These problems have created a negative impact on the productivity and utilization of many industries around the country. This paper studies the implementation levels of the manufacturing control systems known as Manufacturing Resource Planning (MRPII) being adapted within some Libyan industries. A survey methodology has been applied for this research, based on the survey analysis, the results pointed out that the system within these industries has a modest strategy towards most of the areas that are considered as being very crucial in implementing these systems successfully. The findings also show a variation within these implementation levels with a respect to the key-elements that related to MRPII, giving the highest levels in the emphasise on financial data accuracy. The paper has also identified limitations within the investigated manufacturing and managerial areas and has pointed to where senior managers should take immediate actions in order to achieve effective implementation of MRPII within their business area.

Keywords: Control, Industry, Manufacturing, Survey, System

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Authors: M. Othman, N. Bhuiyan, G. J. Gouw

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In today-s global and competitive market, manufacturing companies are working hard towards improving their production system performance. Most companies develop production systems that can help in cost reduction. Manufacturing systems consist of different elements including production methods, machines, processes, control and information systems. Human issues are an important part of manufacturing systems, yet most companies do not pay sufficient attention to them. In this paper, a workforce planning (WP) model is presented. A non-linear programming model is developed in order to minimize the hiring, firing, training and overtime costs. The purpose is to determine the number of workers for each worker type, the number of workers trained, and the number of overtime hours. Moreover, a decision support system (DSS) based on the proposed model is introduced using the Excel-Lingo software interfacing feature. This model will help to improve the interaction between the workers, managers and the technical systems in manufacturing.

Keywords: Decision Support System, Human Factors, Manufacturing System, Workforce Planning.

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Authors: S. Minhas, C. Juzek, U. Berger

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The planning in manufacturing system is becoming complicated day by day due to the expanding networks and shortage of skilled people to manage change. Consequently, faster lead time and rising demands for eco-efficient evaluation of manufacturing products and processes need exploitation of new and intelligent knowledge management concepts for manufacturing planning. This paper highlights motivation for incorporation of new features in the manufacturing planning system. Furthermore, it elaborates requirements for the development of intelligent knowledge management concept to support planning related decisions. Afterwards, the derived concept is presented in this paper considering two case studies. The first case study is concerned with the automotive ramp-up planning. The second case study specifies requirements for knowledge management system to support decisions in eco-efficient evaluation of manufacturing products and processes

Keywords: Ramp-up, Environmental impact, Knowledge management.

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Authors: Ali Reza Sahab, Amir Gholami Pastaki

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In this paper, backstepping method (BM) is proposed for a single-link flexible mechanical manipulator. In each step of this method a positive value is obtained. Selections of the gain factor values are very important because controller will have different behavior for each different set of values. Improper selection of these gains can lead to instability of the system. In order to choose proper values for gains BELBIC method has been used in this work. Finally, to prove the efficiency of this method, the obtained results of proposed model are compared with robust controller one. Results show that the combination of backstepping and BELBIC that is presented here, can stabilized the system with higher speed, shorter settling time and lower overshoot in than robust controller.

Keywords: single-link flexible manipulator, backstepping, BELBIC

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Authors: Carlos J. Costa, Manuela Aparício

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In this paper, we present the information life cycle, and analyze the importance of managing the corporate application portfolio across this life cycle. The approach presented here does not correspond just to the extension of the traditional information system development life cycle. This approach is based in the generic life cycle employed in other contexts like manufacturing or marketing. In this paper it is proposed a model of an information system life cycle, supported in the assumption that a system has a limited life. But, this limited life may be extended. This model is also applied in several cases; being reported here two examples of the framework application in a construction enterprise, and in a manufacturing enterprise.

Keywords: Information systems/technology, informatio nsystems life cycle, organization engineering, information economics.

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Authors: Chia-Hui Huang, Han-Ying Kao

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In production planning (PP) periods with excess capacity and growing demand, the manufacturers have two options to use the excess capacity. First, it could do more changeovers and thus reduce lot sizes, inventories, and inventory costs. Second, it could produce in excess of demand in the period and build additional inventory that can be used to satisfy future demand increments, thus delaying the purchase of the next machine that is required to meet the growth in demand. In this study we propose an enhanced supply chain planning model with flexible planning capability. In addition, a 3D supply chain planning system is illustrated.

Keywords: Supply chain, capacity expansion, inventory management, planning system.

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Authors: A. Aizpurua, W. Koutstaal

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In this study, we examined gender differences in: (1) a flexible remembering task, that asked for episodic memory decisions at an item-specific versus category-based level, and (2) the retrieval specificity of autobiographical memory during free recall. Differences favouring women were found on both measures. Furthermore, a significant association was observed, across gender groups, between level of specificity in the autobiographical memory interview and sensitivity to gist on the flexible remembering task. These results suggest that similar cognitive processes may partially contribute to both the ability for specific autobiographical recall and the capacity for inhibition of gist-information on the flexible remembering task.

Keywords: autobiographical memory, flexible remembering, gender, specificity.

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Authors: Sepideh Jabbari Behnam, Zahrasadat Saide Zarabadi

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A city is an intertwined texture from the relationship of different components in a whole which is united in a one, so designing the whole complex and its planning is not an easy matter. By considering that a city is a complex system with infinite components and communications, providing flexible layouts that can respond to the unpredictable character of the city, which is a result of its complexity, is inevitable. Parametric design approach as a new approach can produce flexible and transformative layouts in any stage of design. This study aimed to introduce parametric design as a modern approach to respond to complex urban issues by using descriptive and analytical methods. This paper firstly introduces complex systems and then giving a brief characteristic of complex systems. The flexible design and layout flexibility is another matter in response and simulation of complex urban systems that should be considered in design, which is discussed in this study. In this regard, after describing the nature of the parametric approach as a flexible approach, as well as a tool and appropriate way to respond to features such as limited predictability, reciprocating nature, complex communications, and being sensitive to initial conditions and hierarchy, this paper introduces parametric design.

Keywords: Complexity theory, complex system, flexibility, parametric design.

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Authors: N. Javadian, J. Rezaeian, Y. Maali

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In this paper a multi-objective nonlinear programming model of cellular manufacturing system is presented which minimize the intercell movements and maximize the sum of reliability of cells. We present a genetic approach for finding efficient solutions to the problem of cell formation for products having multiple routings. These methods find the non-dominated solutions and according to decision makers prefer, the best solution will be chosen.

Keywords: Cellular Manufacturing, Genetic Algorithm, Multiobjective, Life-Cycle.

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