Search results for: Flexible setup.

Authors: Kai-Chao Yang, Chun-Ming Huang, Chih-Chiao Yang, Chien-Ming Wu

Abstract:

Sensors have been used in various kinds of academic fields and applications. In this article, we propose the idea of modularized sensors that combine multiple sensor modules into a unique sensor. We divide a sensor into several units according to functionalities. Each unit has different sensor modules, which share the same type of connectors and can be serially and arbitrarily connected each other. A user can combine different sensor modules into a sensor platform according to requirements. Compared with current modularized sensors, the proposed sensor platform is highly flexible and reusable. We have implemented the prototype of the proposed sensor platform, and the experimental results show the proposed platform can work correctly.

Keywords: Sensor device, sensor fusion.

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Authors: S. G. Ponnambalam, Low Seng Kiat

Abstract:

In this paper, a particle swarm optimization (PSO) algorithm is proposed to solve machine loading problem in flexible manufacturing system (FMS), with bicriterion objectives of minimizing system unbalance and maximizing system throughput in the occurrence of technological constraints such as available machining time and tool slots. A mathematical model is used to select machines, assign operations and the required tools. The performance of the PSO is tested by using 10 sample dataset and the results are compared with the heuristics reported in the literature. The results support that the proposed PSO is comparable with the algorithms reported in the literature.

Keywords: Machine loading problem, FMS, Particle Swarm Optimization.

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Authors: Roman Ružarovský, Radovan Holubek, Peter Košťál

Abstract:

The current trend of increasing quality and demands of the final product is affected by time analysis of the entire manufacturing process. The primary requirement of manufacturing is to produce as many products as soon as possible, at the lowest possible cost, but of course with the highest quality. Such requirements may be satisfied only if all the elements entering and affecting the production cycle are in a fully functional condition. These elements consist of sensory equipment and intelligent control elements that are essential for building intelligent manufacturing systems. The intelligent manufacturing paradigm includes a new approach to production system structure design. Intelligent behaviors are based on the monitoring of important parameters of system and its environment. The flexible reaction to changes. The realization and utilization of this design paradigm as an "intelligent manufacturing system" enables the flexible system reaction to production requirement as soon as environmental changes too. Results of these flexible reactions are a smaller layout space, be decreasing of production and investment costs and be increasing of productivity. Intelligent manufacturing system itself should be a system that can flexibly respond to changes in entering and exiting the process in interaction with the surroundings.

Keywords: Sensory equipment, intelligent manufacturing systems, manufacturing process, control system, smart automation.

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Authors: G. Bhushan

Abstract:

Multilobe bearings are found to be more stable than circular bearings. A three lobe bearing also possesses good stability characteristics. Sometimes the line of action of the load does not pass through the axis of a bearing and is shifted on either side by a few degrees. Load orientation is one of the factors that affect the stability of a three lobe bearing. The effect of load orientation on the stability of a three-lobe has been discussed in this paper. The results show that stability of a three-lobe bearing supporting either rigid or flexible rotor is increased for the positive values of load orientation i.e. when the load line is shifted in the opposite direction of rotation.

Keywords: Thee-lobe bearing, load orientation, finite element method.

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Authors: Nasr Al-Hinai, Tarek Y. ElMekkawy

Abstract:

The performance of schedules released to a shop floor may greatly be affected by unexpected disruptions. Thus, this paper considers the flexible job shop scheduling problem when processing times of some operations are represented by a uniform distribution with given lower and upper bounds. The objective is to find a predictive schedule that can deal with this uncertainty. The paper compares two genetic approaches to obtain predictive schedule. To determine the performance of the predictive schedules obtained by both approaches, an experimental study is conducted on a number of benchmark problems.

Keywords: Genetic algorithm, met-heuristic, robust scheduling, uncertainty of processing times

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Authors: Wayan F. Mahmudy, Romeo M. Marian, Lee H. S. Luong

Abstract:

This paper and its companion (Part 2) deal with modeling and optimization of two NP-hard problems in production planning of flexible manufacturing system (FMS), part type selection problem and loading problem. The part type selection problem and the loading problem are strongly related and heavily influence the system-s efficiency and productivity. The complexity of the problems is harder when flexibilities of operations such as the possibility of operation processed on alternative machines with alternative tools are considered. These problems have been modeled and solved simultaneously by using real coded genetic algorithms (RCGA) which uses an array of real numbers as chromosome representation. These real numbers can be converted into part type sequence and machines that are used to process the part types. This first part of the papers focuses on the modeling of the problems and discussing how the novel chromosome representation can be applied to solve the problems. The second part will discuss the effectiveness of the RCGA to solve various test bed problems.

Keywords: Flexible manufacturing system, production planning, part type selection problem, loading problem, real-coded genetic algorithm

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Authors: D. R. Delgado Sobrino, R. Holubek, R. Ružarovský

Abstract:

In the past years, the world has witnessed significant work in the field of Manufacturing. Special efforts have been made in the implementation of new technologies, management and control systems, among many others which have all evolved the field. Closely following all this, due to the scope of new projects and the need of turning the existing flexible ideas into more autonomous and intelligent ones, i.e.: moving toward a more intelligent manufacturing, the present paper emerges with the main aim of contributing to the analysis and a few customization issues of a new iCIM 3000 system at the IPSAM. In this process, special emphasis in made on the material flow problem. For this, besides offering a description and analysis of the system and its main parts, also some tips on how to define other possible alternative material flow scenarios and a partial analysis of the combinatorial nature of the problem are offered as well. All this is done with the intentions of relating it with the use of simulation tools, for which these have been briefly addressed with a special focus on the Witness simulation package. For a better comprehension, the previous elements are supported by a few figures and expressions which would help obtaining necessary data. Such data and others will be used in the future, when simulating the scenarios in the search of the best material flow configurations.

Keywords: Flexible/Intelligent assembly/disassembly cell (F/IA/DC), Flexible/Intelligent Manufacturing Systems/Cell (F/IMS/C), Material Flow Optimization/Combinations/Design (MFO/C/D).

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Authors: Manpreet Singh, Parvinder Singh, Sumitter Bir Singh

Abstract:

The emergence of information technology has resulted in an ever-increasing demand to use computers for the efficient management and dissemination of information. Keeping in view the strong need of farmers to collect important and updated information for interactive, flexible and quick decision-making, a model of Decision Support System for Farm Management is developed. The paper discusses the use of Internet technology for the farmers to take decisions. A model is developed for the farmers to access online interactive and flexible information for their farm management. The workflow of the model is presented highlighting the information transfer between different modules.

Keywords: Decision Support System, dissemination.

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Authors: M. Pala Prasad Reddy, Jeevamma Jacob

Abstract:

Accurate dynamic modeling and analysis of flexible link manipulator (FLM) with non linear dynamics is very difficult due to distributed link flexibility and few studies have been conducted based on assumed modes method (AMM) and finite element models. In this paper a nonlinear dynamic model with first two elastic modes is derived using combined Euler/Lagrange and AMM approaches. Significant dynamics associated with the system such as hub inertia, payload, structural damping, friction at joints, combined link and joint flexibility are incorporated to obtain the complete and accurate dynamic model. The response of the FLM to the applied bang-bang torque input is compared against the models derived from LS-DYNA finite element discretization approach and linear finite element models. Dynamic analysis is conducted using LS-DYNA finite element model which uses the explicit time integration scheme to simulate the system. Parametric study is conducted to show the impact payload mass. A numerical result shows that the LS-DYNA model gives the smooth hub-angle profile.

 

Keywords: Flexible link manipulator, AMM, FEM, LS-DYNA, Bang-bang torque input.

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Authors: Flora Elvistia Firdaus

Abstract:

Polyurethane foams (PUF) has been prepared from vegetable; soybean based polyols. They were characterized into flexible and semi rigid polyurethane foam. This work is directed to production of flexible polyurethane foams by a process involving the reaction of mixture of 2,4- and 2,6-Toluene di Isocyanate isomers, with portion of to blends of soy polyols with petroleum polyol in the presence of other ingredients such as blowing agents, silicone surfactants and accelerating agents. Additon of chain extender improves the property then further decreases the properties on further addition of the same. The objective of this work was to study the effect of chain extender and role of phosphoric acid catalyst to the final properties and correlate the morphology image with mechanical properties of these foams.

Keywords: polyurethane, soy polyol, chain extender

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Authors: Cesar H. Ortega Jimenez, Ignacio Eguia Salinas, Pedro Garrido Vega, Jose A. Dominguez Machuca

Abstract:

The aim of this study is to identify the conditions of implementation for reconfigurability in summarizing past flexible manufacturing systems (FMS) research by drawing overall conclusions from many separate High Performance Manufacturing (HPM) studies. Meta-analysis will be applied to links between HPM programs and their practices related to FMS and manufacturing performance with particular reference to responsiveness performance. More specifically, an application of meta-analysis will be made with reference to two of the main steps towards the development of an empirically-tested theory: testing the adequacy of the measurement of variables and testing the linkages between the variables.

Keywords: FMS (flexible manufacturing system), HPM (highperformance manufacturing), reconfigurability, RMS (reconfigurablemanufacturing system), responsiveness

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Authors: Csaba Tóth, Éva Lakatos, László Pethő, Seoyoung Cho

Abstract:

The temperature effect on asphalt pavement structure is a crucial factor at the design stage. In this paper, by applying the German guidelines for temperature along the asphalt depth is estimated. The aim is to consider temperature profiles in different seasons in numerical modelling. The model is built with an elastic and isotropic solid element with 19 subdivisions of asphalt layers to reflect the temperature variation. Comparison with the simple three-layer pavement system (asphalt layers, base, and subgrade layers) will be followed to see the difference in result without temperature variation along with the depth. Finally, the fatigue life calculation was checked to prove the validity of the methodology of considering the temperature in the numerical modelling.

Keywords: Temperature profile, flexible pavement modelling, finite element method, temperature modelling.

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Authors: R.A.Mahdavinejad

Abstract:

In this paper, multi-processors job shop scheduling problems are solved by a heuristic algorithm based on the hybrid of priority dispatching rules according to an ant colony optimization algorithm. The objective function is to minimize the makespan, i.e. total completion time, in which a simultanous presence of various kinds of ferons is allowed. By using the suitable hybrid of priority dispatching rules, the process of finding the best solution will be improved. Ant colony optimization algorithm, not only promote the ability of this proposed algorithm, but also decreases the total working time because of decreasing in setup times and modifying the working production line. Thus, the similar work has the same production lines. Other advantage of this algorithm is that the similar machines (not the same) can be considered. So, these machines are able to process a job with different processing and setup times. According to this capability and from this algorithm evaluation point of view, a number of test problems are solved and the associated results are analyzed. The results show a significant decrease in throughput time. It also shows that, this algorithm is able to recognize the bottleneck machine and to schedule jobs in an efficient way.

Keywords: Job shops scheduling, Priority dispatching rules, Makespan, Hybrid heuristic algorithm.

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Authors: Amin Chegenizadeh, Mahdi Keramatikerman, Hamid Nikraz

Abstract:

Pavement engineering plays a significant role to develop cost effective and efficient highway and road networks. In general, pavement regarding structure is categorized in two core group namely flexible and rigid pavements. There are various benefits in application of rigid pavement. For instance, they have a longer life and lower maintenance costs in compare with the flexible pavement. In rigid pavement designs, temperature and thickness are two effective parameters that could widely affect the total cost of the project. In this study, a numerical modeling using Kenpave-Kenslab was performed to investigate the effect of these two important parameters in the rigid pavement.   

Keywords: Rigid pavement, Kenpave, Kenslab, thickness, temperature.

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Authors: Prabhakar Sathujoda

Abstract:

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: Vít Lédl, Tomáš Vít, Pavel Psota, Roman Doleček

Abstract:

The presented paper shows the possibility of using holographic interferometry for measurement of temperature field in moving fluids. There are a few methods for identification of velocity fields in fluids, such us LDA, PIV, hot wire anemometry. It is very difficult to measure the temperature field in moving fluids. One of the often used methods is Constant Current Anemometry (CCA), which is a point temperature measurement method. Data are possibly acquired at frequencies up to 1000Hz. This frequency should be limiting factor for using of CCA in fluid when fast change of temperature occurs. This shortcoming of CCA measurements should be overcome by using of optical methods such as holographic interferometry. It is necessary to employ a special holographic setup with double sensitivity instead of the commonly used Mach-Zehnder type of holographic interferometer in order to attain the parameters sufficient for the studied case. This setup is not light efficient like the Mach-Zehnder type but has double sensitivity. The special technique of acquiring and phase averaging of results from holographic interferometry is also presented. The results from the holographic interferometry experiments will be compared with the temperature field achieved by methods CCA method.

Keywords: Holographic interferometry, pulsatile flow, temperature measurement, hot-wire anemometry

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Authors: S. Feli, S. Tavousi Tafreshi, A. Ghasemi

Abstract:

The present paper aims at evaluating the response of three-dimensional buildings with in-plan stiffness irregularities that have been subjected to two-way excitation ground motion records simultaneously. This study is broadly-based fragility assessment with greater emphasis on structural response at in-plan flexible and stiff sides. To this end, three type of three-dimensional 5-story steel building structures with stiffness eccentricities, were subjected to extensive nonlinear incremental dynamic analyses (IDA) utilizing Ibarra-Krawinkler deterioration models. Fragility assessment was implemented for different configurations of braces to investigate the losses in buildings with center of resisting (CR) eccentricities.

Keywords: Ibarra Krawinkler, fragility assessment, flexible and stiff side, center of resisting.

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Authors: Sumit Kumar, Sunil Kumar, Chandan Deep Singh

Abstract:

This paper presents modeling and simulation of flexible robot in an underwater environment. The underwater environment completely contrasts with ground or space environment. The robot in an underwater situation is subjected to various dynamic forces like buoyancy forces, hydrostatic and hydrodynamic forces. The underwater robot is modeled as Rayleigh beam. The developed model further allows estimating the deflection of tip in two directions. The complete dynamics of the underwater robot is analyzed, which is the main focus of this investigation. The control of robot trajectory is not discussed in this paper. Simulation is performed using Symbol Shakti software.

Keywords: Bond graph modeling, dynamics. modeling, Rayleigh beam, underwater robot.

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Authors: Joanna Nieżurawska, Hanna Karaszewska, Anna Dziadkiewicz

Abstract:

Contemporary conditions force companies to constantly implement changes and improvements, which is connected with plasticization of their activity in all spheres. Cafeteria systems are a good example of flexible remuneration systems. Cafeteria systems are well-known and often used in the United States, Great Britain and in Western Europe. In Poland, they are hardly ever used and greater flexibility in remuneration packages refers mainly to senior managers and executives. The main aim of this article is to research the attractiveness of the cafeteria system as viewed by generation Z. The additional aim of the article is to prioritize using the importance index of particular types of cafeteria systems from the generation Z’s perspective, as well as to identify the factors which determine the development of cafeteria systems in Poland. The research was conducted in June 2015 among 185 young employees (generation Z). The paper presents some of the results.

Keywords: Cafeteria, generation X, generation Y, generation Z, flexible remuneration systems, plasticization of remuneration.

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Authors: Wayan F. Mahmudy, Romeo M. Marian, Lee H. S. Luong

Abstract:

This paper presents modeling and optimization of two NP-hard problems in flexible manufacturing system (FMS), part type selection problem and loading problem. Due to the complexity and extent of the problems, the paper was split into two parts. The first part of the papers has discussed the modeling of the problems and showed how the real coded genetic algorithms (RCGA) can be applied to solve the problems. This second part discusses the effectiveness of the RCGA which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.

Keywords: Flexible manufacturing system, production planning, part type selection problem, loading problem, real-coded genetic algorithm

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Authors: T. Karech A. Noui, T. Bouzid

Abstract:

This article presents a comparative study by numerical analysis of the behavior of reinforcements of clayey soils by flexible columns (stone columns) and rigid columns (piles). The numerical simulation was carried out in 3D for an assembly of foundation, columns and a pile of a bridge. Particular attention has been paid to take into account the installation of the columns. Indeed, in practice, due to the compaction of the column, the soil around it sustains a lateral expansion and the horizontal stresses are increased. This lateral expansion of the column can be simulated numerically. This work represents a comparative study of the interaction between the soil on one side, and the two types of reinforcement on the other side, and their influence on the behavior of the soil and of the pile of a bridge.

Keywords: Piles, stone columns, interaction, foundation, settlement, consolidation.

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Authors: Wayan F. Mahmudy, Romeo M. Marian, Lee H. S. Luong

Abstract:

 This paper deals with modeling and optimization of two NP-hard problems in production planning of flexible manufacturing system (FMS), part type selection problem and loading problem. The part type selection problem and the loading problem are strongly related and heavily influence the system’s efficiency and productivity. These problems have been modeled and solved simultaneously by using real coded genetic algorithms (RCGA) which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.

Keywords: Flexible manufacturing system, production planning, part type selection problem, loading problem, real-coded genetic algorithm.

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Authors: Fathilah binti Ali, Jamarosliza Jamaluddin, Arun Kumar Upadhyay

Abstract:

Poly(lactic acid) (PLA) is a biodegradable polymer which has good mechanical properties, however, its brittleness limits its usage especially in packaging materials. Therefore, in this work, PLA based polyurethane films were prepared by synthesizing with different types of isocyanates; methylene diisocyanate (MDI) and hexamethylene diisocyanates (HDI). For this purpose, PLA based polyurethane must have good strength and flexibility. Therefore, polycaprolactone which has better flexibility were prepared with PLA. An effective way to endow polylactic acid with toughness is through chain-extension reaction of the polylactic acid pre-polymer with polycaprolactone used as chain extender. Polyurethane prepared from MDI showed brittle behaviour, while, polyurethane prepared from HDI showed flexibility at same concentrations.

Keywords: Biodegradable polymer, flexible, poly(lactic acid), polyurethane.

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Authors: Jawad Alzeer

Abstract:

Cultural setup is varied from country to country and nation to nation, but the ability to adapt successfully to the new cultural setup may pave the way toward the development of cultural intelligence. Overcoming differences may require to build up our personality with the ability to learn, exchange thoughts, and have a constructive dream. Adaptation processes can be accelerated if we effectively utilize our cultural diversity. This can be done through a unified body or society; people with common goals can collectively work to satisfy their values. Narrowing the gap between developed and developing countries is of prime importance. Many international organizations are trying to resolve these issues by rational and peaceful means. Failing to understand the cultural differences, mentalities, strengths and weaknesses of developed and developing countries led to the collapse of many partnerships. Establishment of a neutral body influenced by developed countries intellectuality and developing countries personality may offer a better understanding and reasonable solutions, suggestions, advice that may assist in narrowing gaps and promote-strengthening relationship between developed and developing countries. The key issues, goals, and potential concepts associated with initiating Swiss scientific society for developing countries as a model to facilitate integration of highly skilled scientists are discussed.

Keywords: Cultural diversity, developing countries, integration, Switzerland.

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Authors: J. Soini, P. Sillberg, J. Raitaniemi

Abstract:

The task of strategic information technology management is to focus on adapting technology to ensure competitiveness. A key factor for success in this sector is awareness and readiness to deploy new technologies and exploit the services they offer. Recently, the need for more flexible and dynamic user interfaces (UIs) has been recognized, especially in mobile applications. An ongoing research project (MOP), initiated by TUT in Finland, is looking at how mobile device UIs can be adapted for different needs and contexts. It focuses on examining the possibilities to develop adapter software for solving the challenges related to the UI and its flexibility in mobile devices. This approach has great potential for enhancing information transfer in mobile devices, and consequently for improving information management. The technology presented here could be one of the key emerging technologies in the information technology sector in relation to mobile devices and telecommunications.

Keywords: Emerging technologies, Flexible user interfaces, Information management, Information technology, Mobile technology.

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Authors: Barbara Kilosanidze, George Kakauridze, Levan Nadareishvili, Yuri Mshvenieradze

Abstract:

A new method for determining the distribution of birefringence and linear dichroism in optical polymer materials is presented. The method is based on the use of polarizationholographic diffraction grating that forms an orthogonal circular basis in the process of diffraction of probing laser beam on the grating. The intensities ratio of the orders of diffraction on this grating enables the value of birefringence and linear dichroism in the sample to be determined. The distribution of birefringence in the sample is determined by scanning with a circularly polarized beam with a wavelength far from the absorption band of the material. If the scanning is carried out by probing beam with the wavelength near to a maximum of the absorption band of the chromophore then the distribution of linear dichroism can be determined. An appropriate theoretical model of this method is presented. A laboratory setup was created for the proposed method. An optical scheme of the laboratory setup is presented. The results of measurement in polymer films with two-dimensional gradient distribution of birefringence and linear dichroism are discussed.

Keywords: Birefringence, graded oriented polymers, linear dichroism, optical polymers, optical anisotropy, polarization-holographic grating,

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Authors: E. Farjami, La. Mohammadzadeh Afshar, Li. Mohammadzade Afshar, A. Taran

Abstract:

Nowadays, flexibility introduced as a modern technology in furniture systems especially in interior planning design. According to results, the most important impact of these systems can be seen on open plan design that makes workspaces comfortable and increases the productivity of employees besides making good relationship between them. Briefly, there are some factors along with new systems in furniture design help create inappropriate space to make working better and easier while it has modular planning organization. It brings about some approaches to have a successful space for open offices with modular design and flexible furniture systems. These approaches have been investigated in open and close offices at Eastern Mediterranean University (EMU) in Famagusta, Cyprus, using information extracted from questionnaires.

Keywords: Flexibility, Flexible Furniture, Modular design, Open offices, Modular furniture systems.

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Authors: Imran Sarwar Bajwa, Rafaqut Kazmi, Shahzad Mumtaz, M. Abbas Choudhary, M. Shahid Naweed

Abstract:

Business Process Management (BPM) helps in optimizing the business processes inside an enterprise. But BPM architecture does not provide any help for extending the enterprise. Modern business environments and rapidly changing technologies are asking for brisk changes in the business processes. Service Oriented Architecture (SOA) can help in enabling the success of enterprise-wide BPM. SOA supports agility in software development that is directly related to achieve loose coupling of interacting software agents. Agility is a premium concern of the current software designing architectures. Together, BPM and SOA provide a perfect combination for enterprise computing. SOA provides the capabilities for services to be combined together and to support and create an agile, flexible enterprise. But there are still many questions to answer; BPM is better or SOA? and what is the future track of BPM and SOA? This paper tries to answer some of these important questions.

Keywords: Information Systems, BPM, SOA, Process management, IT management.

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Authors: Muhammad I. Ibrahimy, Mamun B.I. Reaz, Khandaker Asaduzzaman, Sazzad Hussain

Abstract:

An approach to develop the FPGA of a flexible key RSA encryption engine that can be used as a standard device in the secured communication system is presented. The VHDL modeling of this RSA encryption engine has the unique characteristics of supporting multiple key sizes, thus can easily be fit into the systems that require different levels of security. A simple nested loop addition and subtraction have been used in order to implement the RSA operation. This has made the processing time faster and used comparatively smaller amount of space in the FPGA. The hardware design is targeted on Altera STRATIX II device and determined that the flexible key RSA encryption engine can be best suited in the device named EP2S30F484C3. The RSA encryption implementation has made use of 13,779 units of logic elements and achieved a clock frequency of 17.77MHz. It has been verified that this RSA encryption engine can perform 32-bit, 256-bit and 1024-bit encryption operation in less than 41.585us, 531.515us and 790.61us respectively.

Keywords: RSA, FPGA, Communication, Security, VHDL.

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Authors: Christopher C. Ihueze, Charles C. Okpala, Christian E. Okafor, Peter O. Ogbobe

Abstract:

This paper focuses on robust design and optimization of industrial production wastes. Past literatures were reviewed to case study Clamason Industries Limited (CIL) - a leading ladder-tops manufacturer. A painstaking study of the firm-s practices at the shop floor revealed that Over-production, Waiting time, Excess inventory, and Defects are the major wastes that are impeding their progress and profitability. Design expert8 software was used to apply Taguchi robust design and response surface methodology in order to model, analyse and optimise the wastes cost in CIL. Waiting time and overproduction rank first and second in contributing to the costs of wastes in CIL. For minimal wastes cost the control factors of overproduction, waiting-time, defects and excess-inventory must be set at 0.30, 390.70, 4 and 55.70 respectively for CIL. The optimal value of cost of wastes for the months studied was 22.3679. Finally, a recommendation was made that for the company to enhance their profitability and customer satisfaction, they must adopt the Shingeo Shingo-s Single Minute Exchange of Dies (SMED), which will immediately tackle the waste of waiting by drastically reducing their setup time.

Keywords: Excess-inventory, setup time, single minute exchange of dies, optimal value, over-production, robust design.

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