Search results for: Equipment manufacturing
1101 A New Approach to Workforce Planning
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.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 25471100 Multi-Objective Cellular Manufacturing System under Machines with Different Life-Cycle using Genetic Algorithm
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.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 19441099 Efficient Utilization of Unmanned Aerial Vehicle (UAV) for Fishing through Surveillance for Fishermen
Authors: T. Ahilan, V. Aswin Adityan, S. Kailash
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UAV’s are small remote operated or automated aerial surveillance systems without a human pilot aboard. UAV’s generally finds its use in military and special operation application, a recent growing trend in UAV’s finds its application in several civil and nonmilitary works such as inspection of power or pipelines. The objective of this paper is the augmentation of a UAV in order to replace the existing expensive sonar (Sound Navigation And Ranging) based equipment amongst small scale fisherman, for whom access to sonar equipment are restricted due to limited economic resources. The surveillance equipment’s present in the UAV will relay data and GPS (Global Positioning System) location onto a receiver on the fishing boat using RF signals, using which the location of the schools of fishes can be found. In addition to this, an emergency beacon system is present for rescue operations and drone recovery.Keywords: GPS, RF signals, School of fish, Sonar, Surveillance UAV, Video stream.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 31701098 Application of the Data Distribution Service for Flexible Manufacturing Automation
Authors: Marco Ryll, Svetan Ratchev
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This paper discusses the applicability of the Data Distribution Service (DDS) for the development of automated and modular manufacturing systems which require a flexible and robust communication infrastructure. DDS is an emergent standard for datacentric publish/subscribe middleware systems that provides an infrastructure for platform-independent many-to-many communication. It particularly addresses the needs of real-time systems that require deterministic data transfer, have low memory footprints and high robustness requirements. After an overview of the standard, several aspects of DDS are related to current challenges for the development of modern manufacturing systems with distributed architectures. Finally, an example application is presented based on a modular active fixturing system to illustrate the described aspects.Keywords: Flexible Manufacturing, Publish/Subscribe, Plug & Produce.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 23521097 Testing a Flexible Manufacturing System Facility Production Capacity through Discrete Event Simulation: Automotive Case Study
Authors: Justyna Rybicka, Ashutosh Tiwari, Shane Enticott
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In the age of automation and computation aiding manufacturing, it is clear that manufacturing systems have become more complex than ever before. Although technological advances provide the capability to gain more value with fewer resources, sometimes utilisation of the manufacturing capabilities available to organisations is difficult to achieve. Flexible manufacturing systems (FMS) provide a unique capability to manufacturing organisations where there is a need for product range diversification by providing line efficiency through production flexibility. This is very valuable in trend driven production set-ups or niche volume production requirements. Although FMS provides flexible and efficient facilities, its optimal set-up is key in achieving production performance. As many variables are interlinked due to the flexibility provided by the FMS, analytical calculations are not always sufficient to predict the FMS’ performance. Simulation modelling is capable of capturing the complexity and constraints associated with FMS. This paper demonstrates how discrete event simulation (DES) can address complexity in an FMS to optimise the production line performance. A case study of an automotive FMS is presented. The DES model demonstrates different configuration options depending on prioritising objectives: utilisation and throughput. Additionally, this paper provides insight into understanding the impact of system set-up constraints on the FMS performance and demonstrates the exploration into the optimal production set-up.
Keywords: Automotive, capacity performance, discrete event simulation, flexible manufacturing system.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 29321096 Loading Methodology for a Capacity Constrained Job-Shop
Authors: Viraj Tyagi, Ajai Jain, P. K. Jain, Aarushi Jain
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This paper presents a genetic algorithm based loading methodology for a capacity constrained job-shop with the consideration of alternative process plans for each part to be produced. Performance analysis of the proposed methodology is carried out for two case studies by considering two different manufacturing scenarios. Results obtained indicate that the methodology is quite effective in improving the shop load balance, and hence, it can be included in the frameworks of manufacturing planning systems of job-shop oriented industries.Keywords: Manufacturing planning, loading, genetic algorithm, Job-Shop
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 14931095 Supply Chain Modeling and Improving Manufacturing Industry in Developing Countries: A Research Agenda
Authors: F.B. Georgise, K. D. Thoben, M. Seifert
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This paper presents a research agenda on the SCOR model adaptation. SCOR model is designated to measure supply chain performance and logistics impact across the boundaries of individual organizations. It is at its growing stage of its life cycle and is enjoying the leverage of becoming the industry standard. The SCOR model has been developed and used widely in developed countries context. This research focuses on the SCOR model adaptation for the manufacturing industry in developing countries. With a necessary understanding of the characteristics, difficulties and problems of the manufacturing industry in developing countries- supply chain; consequently, we will try to designs an adapted model with its building blocks: business process model, performance measures and best practices.Keywords: developing countries, manufacturing industry, SCOR model adaptation
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 22161094 Energy Interaction among HVAC and Supermarket Environment
Authors: D. Woradechjumroen, H. Li, Y. Yu
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Supermarkets are the most electricity-intensive type of commercial buildings. The unsuitable indoor environment of a supermarket provided by abnormal HVAC operations incurs waste energy consumption in refrigeration systems. This current study briefly describes significantly solid backgrounds and proposes easyto- use analysis terminology for investigating the impact of HVAC operations on refrigeration power consumption using the field-test data obtained from building automation system (BAS). With solid backgrounds and prior knowledge, expected energy interactions between HVAC and refrigeration systems are proposed through Pearson’s correlation analysis (R value) by considering correlations between equipment power consumption and dominantly independent variables (driving force conditions).The R value can be conveniently utilized to evaluate how strong relations between equipment operations and driving force parameters are. The calculated R values obtained from field data are compared to expected ranges of R values computed by energy interaction methodology. The comparisons can separate the operational conditions of equipment into faulty and normal conditions. This analysis can simply investigate the condition of equipment operations or building sensors because equipment could be abnormal conditions due to routine operations or faulty commissioning processes in field tests. With systematically solid and easy-to-use backgrounds of interactions provided in the present article, the procedures can be utilized as a tool to evaluate the proper commissioning and routine operations of HVAC and refrigeration systems to detect simple faults (e.g. sensors and driving force environment of refrigeration systems and equipment set-point) and optimize power consumption in supermarket buildings. Moreover, the analysis will be used to further study the FDD research for supermarkets in future.
Keywords: Energy interaction, HVAC, R-value, Supermarket buildings.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 32231093 Barriers of Productivity in Public Sector Automotive Manufacturing Industry of Pakistan
Authors: S. Z. Sarwar, N. Ehsan , I, Mirza, J. L. Piracha, M. Azeem, A. Ishaque
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The public sector losses are the major cause of stagnant growth of Pakistan. Public sector automotive manufacturing industry is one of the major contributors of these losses. This research has been carried out in order to identify the major barriers of productivity of this industry and suggest measures for improvement. This qualitative and quantitative research consisted of informal interviews, discussions augmented by closed ended questionnaire. Three major manufacturing units were chosen for this research and responses from 103 employees were collected. It was found out in this research that numerous productivity flaws exist in the system which requires immediate attention. Besides highlighting flaws this research also suggests corrective actions and areas for future research to overcome these problems.
Keywords: Automotive manufacturing industry, barriers ofproductivity, Public sector losses.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 18761092 The Analysis on Leadership Skills in UK Automobile Manufacturing Enterprises
Authors: Yanting Cao, Kazumitsu Nawata
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The UK has strong economic growth, which attracts other countries to invest there through globalization. This research process will be based on quantitative and qualitative descriptive analysis using interviews. The secondary analysis will involve a case study approach to understand the important aspects of leadership skills. The research outcomes will be identifying the strength and weakness of the leadership skills of UK automobile manufacturing enterprises and suggest the best practices adopted by the respective countries for better results.
Keywords: engineering management, leadership, industrial project management, project managers, automobile manufacturing
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 14161091 Implementation of Technology Concept for the Reduction of Cyanobacteria in Laboratory
Authors: D. Šebo, M. Fedorčáková
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Following the research in the Department of environmental engineering in Faculty of mechanical engineering on Technical University of Kosice and experiences with electrocoagulation style of disposal waste water, there were designed and partly examining the equipment of two stage revitalization on the standing and little fusible water of tenet electrolysis on the little tarns. With the cooperation with vet experts was that manners prove and it is innocuous for animals, during which time cyanobacteria are totally paralyzed. For the implementation of science and research results have been obtained by means EU funds for structural development.
Keywords: Cyanobacteria, Equipment, Pollution, Stagnant Water, Technology
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 13311090 On the Dynamic Model of Service Innovation in Manufacturing Industry
Authors: Yongyoon Suh, Chulhyun Kim, Moon-soo Kim
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As the trend of manufacturing is being dominated depending on services, products and processes are more and more related with sophisticated services. Thus, this research starts with the discussion about integration of the product, process, and service in the innovation process. In particular, this paper sets out some foundations for a theory of service innovation in the field of manufacturing, and proposes the dynamic model of service innovation related to product and process. Two dynamic models of service innovation are suggested to investigate major tendencies and dynamic variations during the innovation cycle: co-innovation and sequential innovation. To structure dynamic models of product, process, and service innovation, the innovation stages in which two models are mainly achieved are identified. The research would encourage manufacturers to formulate strategy and planning for service development with product and process.
Keywords: dynamic model, service innovation, service innovation models, innovation cycle, manufacturing industry.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 20191089 A Proposed Performance Prediction Approach for Manufacturing Processes using ANNs
Authors: M. S. Abdelwahed, M. A. El-Baz, T. T. El-Midany
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this paper aims to provide an approach to predict the performance of the product produced after multi-stages of manufacturing processes, as well as the assembly. Such approach aims to control and subsequently identify the relationship between the process inputs and outputs so that a process engineer can more accurately predict how the process output shall perform based on the system inputs. The approach is guided by a six-sigma methodology to obtain improved performance. In this paper a case study of the manufacture of a hermetic reciprocating compressor is presented. The application of artificial neural networks (ANNs) technique is introduced to improve performance prediction within this manufacturing environment. The results demonstrate that the approach predicts accurately and effectively.Keywords: Artificial neural networks, Reciprocating compressor manufacturing, Performance prediction, Quality improvement
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 17821088 Implementation of A Photo-Curable 3D Additive Manufacturing Technology with Coloring Gray Capability by Using Piezo Ink-Jet
Authors: Ming-Jong Tsai, Y. L. Cheng, Y. L. Kuo, S. Y. Hsiao, J .W. Chen, P. H. Liu, D. H. Chen
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The 3D printing is a combination of digital technology, material science, intelligent manufacturing and control of opto-mechatronics systems. It is called the third industrial revolution from the view of the Economist Journal. A color 3D printing machine may provide the necessary support for high value-added industrial and commercial design, architectural design, personal boutique, and 3D artist’s creation. The main goal of this paper is to develop photo-curable color 3D manufacturing technology and system implementation. The key technologies include (1) Photo-curable color 3D additive manufacturing processes development and materials research (2) Piezo type ink-jet head control and Opto-mechatronics integration technique of the photo-curable color 3D laminated manufacturing system. The proposed system is integrated with single Piezo type ink-jet head with two individual channels for two primary UV light curable color resins which can provide for future colorful 3D printing solutions. The main research results are 16 grey levels and grey resolution of 75 dpi.
Keywords: 3d printing, additive manufacturing, color, photo-curable, Piezo type ink-jet, UV Resin.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 21351087 Development of Reliable Web-Based Laboratories for Developing Countries
Authors: Teyana S. Sapula, Damian D. Haule
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In online context, the design and implementation of effective remote laboratories environment is highly challenging on account of hardware and software needs. This paper presents the remote laboratory software framework modified from ilab shared architecture (ISA). The ISA is a framework which enables students to remotely acccess and control experimental hardware using internet infrastructure. The need for remote laboratories came after experiencing problems imposed by traditional laboratories. Among them are: the high cost of laboratory equipment, scarcity of space, scarcity of technical personnel along with the restricted university budget creates a significant bottleneck on building required laboratory experiments. The solution to these problems is to build web-accessible laboratories. Remote laboratories allow students and educators to interact with real laboratory equipment located anywhere in the world at anytime. Recently, many universities and other educational institutions especially in third world countries rely on simulations because they do not afford the experimental equipment they require to their students. Remote laboratories enable users to get real data from real-time hand-on experiments. To implement many remote laboratories, the system architecture should be flexible, understandable and easy to implement, so that different laboratories with different hardware can be deployed easily. The modifications were made to enable developers to add more equipment in ISA framework and to attract the new developers to develop many online laboratories.Keywords: Batched, ISA, labserver, servicebroker.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 14291086 Considering Assembly Operations and Product Structure for Manufacturing Cell Formation
Authors: M.B. Aryanezhad, J. Aliabadi
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This paper considers the integration of assembly operations and product structure to Cellular Manufacturing System (CMS) design so that to correct the drawbacks of previous researches in the literature. For this purpose, a new mathematical model is developed which dedicates machining and assembly operations to manufacturing cells while the objective function is to minimize the intercellular movements resulting due to both of them. A linearization method is applied to achieve optimum solution through solving aforementioned nonlinear model by common programming language such as Lingo. Then, using different examples and comparing the results, the importance of integrating assembly considerations is demonstrated.Keywords: Assembly operations and Product structure, CellFormation, Genetic Algorithm.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 15861085 Integrating Big Island Layout with Pull System for Production Optimization
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.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 25871084 Managing a Manufacturing System with Integration of Walking Worker and Lean Thinking
Authors: Said Rabah Azzam, Laura Carolina Arias, Shikun Zhou
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A product goes through various processes in a production flow which is also known as assembly line in manufacturing process management. Toyota created a new concept which is known as lean concept in manufacturing industry. Today it is the leading model in manufacturing plants through the globe. The linear walking worker assembly line is a flexible assembly system where 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. This paper attempts to combine the flexibility of the walking worker and lean in order to quantify the benefits from applying the shop floor principles of lean management.
Keywords: Toyota Production System, TPS, LeanManufacturing, Walking Worker, Lean Management, Management, Linear Assembly Lines, U-shaped Assembly Lines, Shop FloorManagement
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 18241083 Vibration Analysis of an Alstom Typhoon Gas Turbine Power Plant Related to Iran Oil Industry
Authors: Omid A. Zargar
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Vibration analysis is the most important factor in preventive maintenance. Gas turbine vibration analysis is also one of the most challenging categories in most critical equipment monitoring systems. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of this kind of equipment developed too much in recent years. On the other hand, too much operation condition consideration in this kind of equipment should be adjusted properly like inlet and outlet pressure and temperature for both turbine and compressor. In this paper the most important tools and hypothesis used for analyzing of gas turbine power plants discussed in details through a real case history related to an Alstom Typhoon gas turbine power plant in Iran oil industries. In addition, the basic principal of vibration behavior caused by mechanical unbalance in gas turbine rotor discussed in details.
Keywords: Vibration analysis, gas turbine, time wave form (TWF), fast Fourier transform (FFT), phase angle.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 49111082 A TISM Model for Structuring the Productivity Elements of Flexible Manufacturing System
Authors: Sandhya Dixit, Tilak Raj
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Flexible Manufacturing System (FMS) is seen as an option for industries which want to boost productivity as well as respond quickly to an increasingly changing marketplace. FMS produces in mid variety, mid volume range and can meet the changing market demands very quickly. But still the impact of adoption of FMS on the productivity of any industry is not very clear. In this paper an attempt has been made to model the various factors affecting the productivity of FMS installation using Total Interpretive Structural Modelling (TISM) Technique.Keywords: Flexible manufacturing system, productivity, total interpretive structural modelling.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 11441081 Coconut Shells as the Alternative Equipment for Foot Reflexology
Authors: Nichanant Sermsri, Chananchida Yuktirat
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This research was the experimental research. Its purpose was to find out how coconut shells can be adapted to be equipment for foot and calf reflexology. The sample group was 58 female street vendors in Thewet Market, Bangkok, selected by selection criteria and voluntary. The data collecting tool was the Visual Analogue Scale. The massaging tool made from coconut shells was the key equipment for this research. The research team assessed the level of exhaustion and heart rate among sample group before and after the massage, then analyzed the data by mean, standard deviation and paired sample t-test.
We found out from the research that
- The level of exhaustion decreased 4.529 levels after the massage and the standard deviation was 1.6195. The heart rates went down 11.67 times/minute and the standard deviation was 6.742.
- The level of exhaustion and heart rate after the massage decreased with the statistically significance at 0.01
Keywords: Coconut Shells, Foot Massage, Foot Reflexology, Massaging Plate.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 18381080 Distributed Manufacturing (DM) - Smart Units and Collaborative Processes
Authors: Hermann Kuehnle
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Applications of the Hausdorff space and its mappings into tangent spaces are outlined, including their fractal dimensions and self-similarities. The paper details this theory set up and further describes virtualizations and atomization of manufacturing processes. It demonstrates novel concurrency principles that will guide manufacturing processes and resources configurations. Moreover, varying levels of details may be produced by up folding and breaking down of newly introduced generic models. This choice of layered generic models for units and systems aspects along specific aspects allows research work in parallel to other disciplines with the same focus on all levels of detail. More credit and easier access are granted to outside disciplines for enriching manufacturing grounds. Specific mappings and the layers give hints for chances for interdisciplinary outcomes and may highlight more details for interoperability standards, as already worked on the international level. The new rules are described, which require additional properties concerning all involved entities for defining distributed decision cycles, again on the base of self-similarity. All properties are further detailed and assigned to a maturity scale, eventually displaying the smartness maturity of a total shopfloor or a factory. The paper contributes to the intensive ongoing discussion in the field of intelligent distributed manufacturing and promotes solid concepts for implementations of Cyber Physical Systems and the Internet of Things into manufacturing industry, like industry 4.0, as discussed in German-speaking countries.
Keywords: Autonomous unit, Networkability, Smart manufacturing unit, Virtualization.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 20741079 Application of Spreadsheet and Queuing Network Model to Capacity Optimization in Product Development
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 systemKeywords: Manufacturing system, product design, spreadsheet model, utilization.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 19201078 Proposal for a Model of Economic Integration for the Development of Industry in Cabinda, Angola
Authors: T. H. Bitebe, T. M. Lima, F. Charrua-Santos, C. J. Matias Oliveira
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This study aims to present a proposal for an economic integration model for the development of the manufacturing industry in Cabinda, Angola. It seeks to analyze the degree of economic integration of Cabinda and the dynamics of the manufacturing industry. Therefore, in the same way, to gather information to support the decision-making for public financing programs that will aim at the disengagement of the manufacturing industry in Angola and Cabinda in particular. The Cabinda Province is the 18th of Angola, the enclave is located in a privileged area of the African and arable land.
Keywords: Economic integration, industrial development, Cabinda industry, Angola.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 8841077 Time and Cost Efficiency Analysis of Quick Die Change System on Metal Stamping Industry
Authors: Rudi Kurniawan Arief
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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.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 11921076 Smart Lean Manufacturing in the Context of Industry 4.0: A Case Study
Authors: M. Ramadan, B. Salah
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This paper introduces a framework to digitalize lean manufacturing tools to enhance smart lean-based manufacturing environments or Lean 4.0 manufacturing systems. The paper discusses the integration between lean tools and the powerful features of recent real-time data capturing systems with the help of Information and Communication Technologies (ICT) to develop an intelligent real-time monitoring and controlling system of production operations concerning lean targets. This integration is represented in the Lean 4.0 system called Dynamic Value Stream Mapping (DVSM). Moreover, the paper introduces the practice of Radio Frequency Identification (RFID) and ICT to smartly support lean tools and practices during daily production runs to keep the lean system alive and effective. This work introduces a practical description of how the lean method tools 5S, standardized work, and poka-yoke can be digitalized and smartly monitored and controlled through DVSM. A framework of the three tools has been discussed and put into practice in a German switchgear manufacturer.Keywords: Lean manufacturing, Industry 4.0, radio frequency identification, value stream mapping.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 31091075 Optimal Manufacturing Scheduling for Dependent Details Processing
Authors: Ivan C. Mustakerov, Daniela I. Borissova
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The increasing competitiveness in manufacturing industry is forcing manufacturers to seek effective processing schedules. The paper presents an optimization manufacture scheduling approach for dependent details processing with given processing sequences and times on multiple machines. By defining decision variables as start and end moments of details processing it is possible to use straightforward variables restrictions to satisfy different technological requirements and to formulate easy to understand and solve optimization tasks for multiple numbers of details and machines. A case study example is solved for seven base moldings for CNC metalworking machines processed on five different machines with given processing order among details and machines and known processing time-s duration. As a result of linear optimization task solution the optimal manufacturing schedule minimizing the overall processing time is obtained. The manufacturing schedule defines the moments of moldings delivery thus minimizing storage costs and provides mounting due-time satisfaction. The proposed optimization approach is based on real manufacturing plant problem. Different processing schedules variants for different technological restrictions were defined and implemented in the practice of Bulgarian company RAIS Ltd. The proposed approach could be generalized for other job shop scheduling problems for different applications.Keywords: Optimal manufacturing scheduling, linear programming, metalworking machines production, dependant details processing.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 14871074 Integration Process of Industrial Design and Engineering Design
Authors: Kazuhide Sugiyama, Hiroshi Osada
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Lately management strategy that put Industrial Design (ID) in its core is recognized more important, as technology and price alone cannot differentiate a product. The needs to shorten the time to develop a product also shorten the development period of ID, and it necessitates the ID process management. This research analyzes the status of integration process of ID and Engineering Design (ED) of office equipment that requires the collaboration of ID and ED to clarify the issues for the efficiency of the development and to propose solutions.
Keywords: Industrial Design (ID), Engineering Design (ED), Integration process, Office equipment
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 18131073 An Overview on Aluminum Matrix Composites: Liquid State Processing
Authors: S. P. Jordan, G. Christian, S. P. Jeffs
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Modern composite materials are increasingly being chosen in replacement of heavier metallic material systems within many engineering fields including aerospace and automotive industries. The increasing push towards satisfying environmental targets are fuelling new material technologies and manufacturing processes. This paper will introduce materials and manufacturing processes using metal matrix composites along with manufacturing processes optimized at Alvant Ltd., based in Basingstoke in the UK which offers modern, cost effective, selectively reinforced composites for light-weighting applications within engineering. An overview and introduction into modern optimized manufacturing methods capable of producing viable replacements for heavier metallic and lower temperature capable polymer composites are offered. A review of the capabilities and future applications of this viable material is discussed to highlight the potential involved in further optimization of old manufacturing techniques, to fully realize the potential to lightweight material using cost-effective methods.Keywords: Aluminum matrix composites, light-weighting, hybrid squeeze casting, strategically placed reinforcements.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 7191072 Fuzzy Hierarchical Clustering Applied for Quality Estimation in Manufacturing System
Authors: Y. Q. Lv, C.K.M. Lee
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This paper develops a quality estimation method with the application of fuzzy hierarchical clustering. Quality estimation is essential to quality control and quality improvement as a precise estimation can promote a right decision-making in order to help better quality control. Normally the quality of finished products in manufacturing system can be differentiated by quality standards. In the real life situation, the collected data may be vague which is not easy to be classified and they are usually represented in term of fuzzy number. To estimate the quality of product presented by fuzzy number is not easy. In this research, the trapezoidal fuzzy numbers are collected in manufacturing process and classify the collected data into different clusters so as to get the estimation. Since normal hierarchical clustering methods can only be applied for real numbers, fuzzy hierarchical clustering is selected to handle this problem based on quality standards.Keywords: Quality Estimation, Fuzzy Quality Mean, Fuzzy Hierarchical Clustering, Fuzzy Number, Manufacturing system
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1667