Search results for: Manufacturing Process
5699 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 29225698 Design and Manufacturing of a Propeller for Axial-Flow Fan
Authors: D. Almazo, M. Toledo, C. Rodríguez
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This work presents a methodology for the design and manufacture of propellers oriented to the experimental verification of theoretical results based on the combined model. The design process begins by using algorithms in Matlab which output data contain the coordinates of the points that define the blade airfoils, in this case the NACA 6512 airfoil was used. The modeling for the propeller blade was made in NX7, through the imported files in Matlab and with the help of surfaces. Later, the hub and the clamps were also modeled. Finally, NX 7 also made possible to create post-processed files to the required machine. It is possible to find the block of numbers with G & M codes about the type of driver on the machine. The file extension is .ptp. These files made possible to manufacture the blade, and the hub of the propeller.Keywords: Airfoil, CAM, manufacturing, mathematical algorithm, numeric control, propeller design, simulation.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 38615697 Parametric Analysis in the Electronic Sensor Frequency Adjustment Process
Authors: Rungchat Chompu-Inwai, Akararit Charoenkasemsuk
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The use of electronic sensors in the electronics industry has become increasingly popular over the past few years, and it has become a high competition product. The frequency adjustment process is regarded as one of the most important process in the electronic sensor manufacturing process. Due to inaccuracies in the frequency adjustment process, up to 80% waste can be caused due to rework processes; therefore, this study aims to provide a preliminary understanding of the role of parameters used in the frequency adjustment process, and also make suggestions in order to further improve performance. Four parameters are considered in this study: air pressure, dispensing time, vacuum force, and the distance between the needle tip and the product. A full factorial design for experiment 2k was considered to determine those parameters that significantly affect the accuracy of the frequency adjustment process, where a deviation in the frequency after adjustment and the target frequency is expected to be 0 kHz. The experiment was conducted on two levels, using two replications and with five center-points added. In total, 37 experiments were carried out. The results reveal that air pressure and dispensing time significantly affect the frequency adjustment process. The mathematical relationship between these two parameters was formulated, and the optimal parameters for air pressure and dispensing time were found to be 0.45 MPa and 458 ms, respectively. The optimal parameters were examined by carrying out a confirmation experiment in which an average deviation of 0.082 kHz was achieved.Keywords: Design of Experiment, Electronic Sensor, Frequency Adjustment, Parametric Analysis
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 13875696 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 18645695 Knowledge Audit Model for Requirement Elicitation Process
Authors: Laleh Taheri, Noraini C. Pa., Rusli Abdullah, Salfarina Abdullah
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Knowledge plays an important role to the success of any organization. Software development organizations are highly knowledge-intensive organizations especially in their requirement elicitation process (REP). There are several problems regarding communicating and using the knowledge in REP such as misunderstanding, being out of scope, conflicting information and changes of requirements. All of these problems occurred in transmitting the requirements knowledge during REP. Several researches have been done in REP in order to solve the problem towards requirements. Knowledge Audit (KA) approaches were proposed in order to solve managing knowledge in human resources, financial and manufacturing. There is lack of study applying the KA in requirements elicitation process. Therefore, this paper proposes a KA model for REP in supporting to acquire good requirements.
Keywords: Knowledge Audit, Requirement Elicitation Process, KA Model, Knowledge in Requirement Elicitation.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 28845694 Novel Use of a Quality Assurance Tool for Integrating Technology to HSE
Authors: Ragi Poyyara, Vivek V., Ashish Khaparde
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The product development process (PDP) in the Technology group plays a very important role in the launch of any product. While a manufacturing process encourages the use of certain measures to reduce health, safety and environmental (HSE) risks on the shop floor, the PDP concentrates on the use of Geometric Dimensioning and Tolerancing (GD&T) to develop a flawless design. Furthermore, PDP distributes and coordinates activities between different departments such as marketing, purchasing, and manufacturing. However, it is seldom realized that PDP makes a significant contribution to developing a product that reduces HSE risks by encouraging the Technology group to use effective GD&T. The GD&T is a precise communication tool that uses a set of symbols, rules, and definitions to mathematically define parts to be manufactured. It is a quality assurance method widely used in the oil and gas sector. Traditionally it is used to ensure the interchangeability of a part without affecting its form, fit, and function. Parts that do not meet these requirements are rejected during quality audits. This paper discusses how the Technology group integrates this quality assurance tool into the PDP and how the tool plays a major role in helping the HSE department in its goal towards eliminating HSE incidents. The PDP involves a thorough risk assessment and establishes a method to address those risks during the design stage. An illustration shows how GD&T helped reduce safety risks by ergonomically improving assembling operations. A brief discussion explains how tolerances provided on a part help prevent finger injury. This tool has equipped Technology to produce fixtures, which are used daily in operations as well as manufacturing. By applying GD&T to create good fits, HSE risks are mitigated for operating personnel. Both customers and service providers benefit from reduced safety risks.
Keywords: HSE, PDP, GD&T, risks.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 18225693 Investigation of a Hybrid Process: Multipoint Incremental Forming
Authors: Safa Boudhaouia, Mohamed Amen Gahbiche, Eliane Giraud, Wacef Ben Salem, Philippe Dal Santo
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Multi-point forming (MPF) and asymmetric incremental forming (ISF) are two flexible processes for sheet metal manufacturing. To take advantages of these two techniques, a hybrid process has been developed: The Multipoint Incremental Forming (MPIF). This process accumulates at once the advantages of each of these last mentioned forming techniques, which makes it a very interesting and particularly an efficient process for single, small, and medium series production. In this paper, an experimental and a numerical investigation of this technique are presented. To highlight the flexibility of this process and its capacity to manufacture standard and complex shapes, several pieces were produced by using MPIF. The forming experiments are performed on a 3-axis CNC machine. Moreover, a numerical model of the MPIF process has been implemented in ABAQUS and the analysis showed a good agreement with experimental results in terms of deformed shape. Furthermore, the use of an elastomeric interpolator allows avoiding classical local defaults like dimples, which are generally caused by the asymmetric contact and also improves the distribution of residual strain. Future works will apply this approach to other alloys used in aeronautic or automotive applications.Keywords: Incremental forming, numerical simulation, MPIF, multipoint forming.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 12995692 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 21225691 Performance Evaluation of Improved Ball End Magnetorheological Finishing Process
Authors: Anant Kumar Singh, Sunil Jha, Pulak M. Pandey
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A novel nanofinishing process using improved ball end magnetorheological (MR) finishing tool was developed for finishing of flat as well as 3D surfaces of ferromagnetic and non ferromagnetic workpieces. In this process a magnetically controlled ball end of smart MR polishing fluid is generated at the tip surface of the tool which is used as a finishing medium and it is guided to follow the surface to be finished through computer controlled 3-axes motion controller. The experiments were performed on ferromagnetic workpiece surface in the developed MR finishing setup to study the effect of finishing time on final surface roughness. The performance of present finishing process on final finished surface roughness was studied. The surface morphology was observed under scanning electron microscopy and atomic force microscope. The final surface finish was obtained as low as 19.7 nm from the initial surface roughness of 142.9 nm. The outcome of newly developed finishing process can be found useful in its applications in aerospace, automotive, dies and molds manufacturing industries, semiconductor and optics machining etc.Keywords: Ball end MR finishing tool, Magnetorheological finishing, Nanofinishing
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 23255690 Effects of Milling Process Parameters on Cutting Forces and Surface Roughness When Finishing Ti6al4v Produced by Electron Beam Melting
Authors: Abdulmajeed Dabwan, Saqib Anwar, Ali Al-Samhan
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Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology, which uses computer-controlled electron beams to create fully dense three-dimensional near-net-shaped parts from metal powder. It gives the ability to produce any complex parts directly from a computer-aided design (CAD) model without tools and dies, and with a variety of materials. However, the quality of the surface finish in EBM process has limitations to meeting the performance requirements of additively manufactured components. The aim of this study is to investigate the cutting forces induced during milling Ti6Al4V produced by EBM as well as the surface quality of the milled surfaces. The effects of cutting speed and radial depth of cut on the cutting forces, surface roughness, and surface morphology were investigated. The results indicated that the cutting speed was found to be proportional to the resultant cutting force at any cutting conditions while the surface roughness improved significantly with the increase in cutting speed and radial depth of cut.
Keywords: Electron beam melting, additive manufacturing, Ti6Al4V, surface morphology.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 6965689 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 15785688 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 25785687 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 11305686 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 20675685 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 19095684 Quality Classification and Monitoring Using Adaptive Metric Distance and Neural Networks: Application in Pickling Process
Authors: S. Bouhouche, M. Lahreche, S. Ziani, J. Bast
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Modern manufacturing facilities are large scale, highly complex, and operate with large number of variables under closed loop control. Early and accurate fault detection and diagnosis for these plants can minimise down time, increase the safety of plant operations, and reduce manufacturing costs. Fault detection and isolation is more complex particularly in the case of the faulty analog control systems. Analog control systems are not equipped with monitoring function where the process parameters are continually visualised. In this situation, It is very difficult to find the relationship between the fault importance and its consequences on the product failure. We consider in this paper an approach to fault detection and analysis of its effect on the production quality using an adaptive centring and scaling in the pickling process in cold rolling. The fault appeared on one of the power unit driving a rotary machine, this machine can not track a reference speed given by another machine. The length of metal loop is then in continuous oscillation, this affects the product quality. Using a computerised data acquisition system, the main machine parameters have been monitored. The fault has been detected and isolated on basis of analysis of monitored data. Normal and faulty situation have been obtained by an artificial neural network (ANN) model which is implemented to simulate the normal and faulty status of rotary machine. Correlation between the product quality defined by an index and the residual is used to quality classification.Keywords: Modeling, fault detection and diagnosis, parameters estimation, neural networks, Fault Detection and Diagnosis (FDD), pickling process.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 15655683 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 8735682 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 11835681 Methodology of Estimating Assembly Cost by MODAPTS
Authors: Heung Jae Cho, Jae Il Park
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This paper presents the development of an MODAPTS based cost estimating system to help designers in estimating the manufacturing cost of a assembly products which is belonged from the workers in working fields. Competitiveness of manufacturing cost is getting harder because of the development of Information and telecommunication, but also globalization. Therefore, the accuracy of the assembly cost estimation is getting important. DFA and MODAPTS is useful method for measuring the working hour. But these two methods are used just as a timetable. Therefore, in this paper, we suggest the process of measuring the working hours by MODAPTS which includes the working field-s accurate information. In addition, we adduce the estimation method of accuracy assembly cost with the real information. This research could be useful for designers that can estimate the assembly cost more accurately, and also effective for the companies that which are concerned to reduce the product cost.
Keywords: Cost estimation, DFA, MODAPTS, Assembly cost
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 39655680 Optimization of Machining Parametric Study on Electrical Discharge Machining
Authors: Rakesh Prajapati, Purvik Patel, Hardik Patel
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Productivity and quality are two important aspects that have become great concerns in today’s competitive global market. Every production/manufacturing unit mainly focuses on these areas in relation to the process, as well as the product developed. The electrical discharge machining (EDM) process, even now it is an experience process, wherein the selected parameters are still often far from the maximum, and at the same time selecting optimization parameters is costly and time consuming. Material Removal Rate (MRR) during the process has been considered as a productivity estimate with the aim to maximize it, with an intention of minimizing surface roughness taken as most important output parameter. These two opposites in nature requirements have been simultaneously satisfied by selecting an optimal process environment (optimal parameter setting). Objective function is obtained by Regression Analysis and Analysis of Variance. Then objective function is optimized using Genetic Algorithm technique. The model is shown to be effective; MRR and Surface Roughness improved using optimized machining parameters.
Keywords: Material removal rate, TWR, OC, DOE, ANOVA, MINITAB.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 8275679 Improved Pattern Matching Applied to Surface Mounting Devices Components Localization on Automated Optical Inspection
Authors: Pedro M. A. Vitoriano, Tito. G. Amaral
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Automated Optical Inspection (AOI) Systems are commonly used on Printed Circuit Boards (PCB) manufacturing. The use of this technology has been proven as highly efficient for process improvements and quality achievements. The correct extraction of the component for posterior analysis is a critical step of the AOI process. Nowadays, the Pattern Matching Algorithm is commonly used, although this algorithm requires extensive calculations and is time consuming. This paper will present an improved algorithm for the component localization process, with the capability of implementation in a parallel execution system.
Keywords: AOI, automated optical inspection, SMD, surface mounting devices, pattern matching, parallel execution.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 10705678 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 30845677 Optimal Bayesian Control of the Proportion of Defectives in a Manufacturing Process
Authors: Viliam Makis, Farnoosh Naderkhani, Leila Jafari
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In this paper, we present a model and an algorithm for the calculation of the optimal control limit, average cost, sample size, and the sampling interval for an optimal Bayesian chart to control the proportion of defective items produced using a semi-Markov decision process approach. Traditional p-chart has been widely used for controlling the proportion of defectives in various kinds of production processes for many years. It is well known that traditional non-Bayesian charts are not optimal, but very few optimal Bayesian control charts have been developed in the literature, mostly considering finite horizon. The objective of this paper is to develop a fast computational algorithm to obtain the optimal parameters of a Bayesian p-chart. The decision problem is formulated in the partially observable framework and the developed algorithm is illustrated by a numerical example.Keywords: Bayesian control chart, semi-Markov decision process, quality control, partially observable process.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 11625676 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 14755675 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 7045674 The Effects of RCA Clean Variables on Particle Removal Efficiency
Authors: Siti Kudnie Sahari, Jane Chai Hai Sing, Khairuddin Ab. Hamid
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Shrunken patterning for integrated device manufacturing requires surface cleanliness and surface smoothness in wet chemical processing [1]. It is necessary to control all process parameters perfectly especially for the common cleaning technique RCA clean (SC-1 and SC-2) [2]. In this paper the characteristic and effect of surface preparation parameters are discussed. The properties of RCA wet chemical processing in silicon technology is based on processing time, temperature, concentration and megasonic power of SC-1 and QDR. An improvement of wafer surface preparation by the enhanced variables of the wet cleaning chemical process is proposed.Keywords: RCA, SC-1, SC-2, QDR
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 32235673 An Evaluation on the Effectiveness of a 3D Printed Composite Compression Mold
Authors: Peng Hao Wang, Garam Kim, Ronald Sterkenburg
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The applications of composite materials within the aviation industry has been increasing at a rapid pace. However, the growing applications of composite materials have also led to growing demand for more tooling to support its manufacturing processes. Tooling and tooling maintenance represents a large portion of the composite manufacturing process and cost. Therefore, the industry’s adaptability to new techniques for fabricating high quality tools quickly and inexpensively will play a crucial role in composite material’s growing popularity in the aviation industry. One popular tool fabrication technique currently being developed involves additive manufacturing such as 3D printing. Although additive manufacturing and 3D printing are not entirely new concepts, the technique has been gaining popularity due to its ability to quickly fabricate components, maintain low material waste, and low cost. In this study, a team of Purdue University School of Aviation and Transportation Technology (SATT) faculty and students investigated the effectiveness of a 3D printed composite compression mold. A 3D printed composite compression mold was fabricated by 3D scanning a steel valve cover of an aircraft reciprocating engine. The 3D printed composite compression mold was used to fabricate carbon fiber versions of the aircraft reciprocating engine valve cover. The 3D printed composite compression mold was evaluated for its performance, durability, and dimensional stability while the fabricated carbon fiber valve covers were evaluated for its accuracy and quality. The results and data gathered from this study will determine the effectiveness of the 3D printed composite compression mold in a mass production environment and provide valuable information for future understanding, improvements, and design considerations of 3D printed composite molds.
Keywords: Additive manufacturing, carbon fiber, composite tooling, molds.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 6835672 Solving Part Type Selection and Loading Problem in Flexible Manufacturing System Using Real Coded Genetic Algorithms – Part I: Modeling
Authors: Wayan F. Mahmudy, Romeo M. Marian, Lee H. S. Luong
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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
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 20985671 Development of Manufacturing Simulation Model for Semiconductor Fabrication
Authors: Syahril Ridzuan Ab Rahim, Ibrahim Ahmad, Mohd Azizi Chik, Ahmad Zafir Md. Rejab, and U. Hashim
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This research presents the development of simulation modeling for WIP management in semiconductor fabrication. Manufacturing simulation modeling is needed for productivity optimization analysis due to the complex process flows involved more than 35 percent re-entrance processing steps more than 15 times at same equipment. Furthermore, semiconductor fabrication required to produce high product mixed with total processing steps varies from 300 to 800 steps and cycle time between 30 to 70 days. Besides the complexity, expansive wafer cost that potentially impact the company profits margin once miss due date is another motivation to explore options to experiment any analysis using simulation modeling. In this paper, the simulation model is developed using existing commercial software platform AutoSched AP, with customized integration with Manufacturing Execution Systems (MES) and Advanced Productivity Family (APF) for data collections used to configure the model parameters and data source. Model parameters such as processing steps cycle time, equipment performance, handling time, efficiency of operator are collected through this customization. Once the parameters are validated, few customizations are made to ensure the prior model is executed. The accuracy for the simulation model is validated with the actual output per day for all equipments. The comparison analysis from result of the simulation model compared to actual for achieved 95 percent accuracy for 30 days. This model later was used to perform various what if analysis to understand impacts on cycle time and overall output. By using this simulation model, complex manufacturing environment like semiconductor fabrication (fab) now have alternative source of validation for any new requirements impact analysis.Keywords: Advanced Productivity Family (APF), Complementary Metal Oxide Semiconductor (CMOS), Manufacturing Execution Systems (MES), Work In Progress (WIP).
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 31965670 Lean Production to Increase Reproducibility and Work Safety in the Laser Beam Melting Process Chain
Authors: C. Bay, A. Mahr, H. Groneberg, F. Döpper
Abstract:
Additive Manufacturing processes are becoming increasingly established in the industry for the economic production of complex prototypes and functional components. Laser beam melting (LBM), the most frequently used Additive Manufacturing technology for metal parts, has been gaining in industrial importance for several years. The LBM process chain – from material storage to machine set-up and component post-processing – requires many manual operations. These steps often depend on the manufactured component and are therefore not standardized. These operations are often not performed in a standardized manner, but depend on the experience of the machine operator, e.g., levelling of the build plate and adjusting the first powder layer in the LBM machine. This lack of standardization limits the reproducibility of the component quality. When processing metal powders with inhalable and alveolar particle fractions, the machine operator is at high risk due to the high reactivity and the toxic (e.g., carcinogenic) effect of the various metal powders. Faulty execution of the operation or unintentional omission of safety-relevant steps can impair the health of the machine operator. In this paper, all the steps of the LBM process chain are first analysed in terms of their influence on the two aforementioned challenges: reproducibility and work safety. Standardization to avoid errors increases the reproducibility of component quality as well as the adherence to and correct execution of safety-relevant operations. The corresponding lean method 5S will therefore be applied, in order to develop approaches in the form of recommended actions that standardize the work processes. These approaches will then be evaluated in terms of ease of implementation and their potential for improving reproducibility and work safety. The analysis and evaluation showed that sorting tools and spare parts as well as standardizing the workflow are likely to increase reproducibility. Organizing the operational steps and production environment decreases the hazards of material handling and consequently improves work safety.
Keywords: Additive manufacturing, lean production, reproducibility, work safety.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 825