Search results for: automotive retailing

Authors: J. D. Burges, M. J. Hall, E. G. Lightsey

Abstract:

A new dual-fluid concept was studied that could eventually find application for cold-gas propulsion for small space satellites or other constant flow applications. In basic form, the concept uses two different refrigerant working fluids, each having a different saturation vapor pressure. The higher vapor pressure refrigerant remains in the saturation phase and is used to pressurize the lower saturation vapor pressure fluid (the propellant) which remains in the compressed liquid phase. A demonstration thruster concept based on this principle was designed and built to study its operating characteristics. An automotive-type electronic fuel injector was used to meter and deliver the propellant. Ejected propellant mass and momentum were measured for several combinations of refrigerants and hydrocarbon fluids. The thruster has the advantage of delivering relatively large total impulse at low tank pressure within a small volume.

Keywords: cold-gas, nano-satellite, R134a, thruster

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Authors: Majid Tolouei-Rad, Ankit Shah

Abstract:

Drilling is the most common machining operation and it forms the highest machining cost in many manufacturing activities including automotive engine production. The outcome of this operation depends upon many factors including utilization of proper cutting tool geometry, cutting tool material and the type of coating used to improve hardness and resistance to wear, and also cutting parameters. With the availability of a large array of tool geometries, materials and coatings, is has become a challenging task to select the best tool and cutting parameters that would result in the lowest machining cost or highest profit rate. This paper describes an algorithm developed to help achieve good performances in drilling operations by automatically determination of proper cutting tools and cutting parameters. It also helps determine machining sequences resulting in minimum tool changes that would eventually reduce machining time and cost where multiple tools are used.

Keywords: Cutting tool, drilling, machining, algorithm.

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

Abstract:

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

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

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Authors: Sarp Erturk, Levent Eyigel, Cihat Celik, Muhammet Sahinoglu, Serdar Ay, Yasin Kaya, Hasan Kaya

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This paper presents a quantitative analysis on the need for automotive calibration methods for digital tachographs. Digital tachographs are mandatory for vehicles used in people and goods transport and they are an important aspect for road safety and inspection. Digital tachographs need to be calibrated for workshops in order for the digital tachograph to display and record speed and odometer values correctly. Calibration of digital tachographs can be performed either manual or automatic. It is shown in this paper that manual calibration of digital tachographs is prone to errors and there can be differences between manual and automatic calibration parameters. Therefore automatic calibration methods are imperative for digital tachograph calibration. The presented experimental results and error analysis clearly support the claims of the paper by evaluating and statistically comparing manual and automatic calibration methods.

Keywords: Digital tachograph, road safety, tachograph calibration, tachograph workshops.

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Authors: Wonsim Cha, Kibum Kim, Kyungwook Choi, Kihyung Lee

Abstract:

A co-generation system in automobile can improve thermal efficiency of vehicle in some degree. The waste heat from the engine exhaust and coolant is still attractive energy source that reaches around 60% of the total energy converted from fuel. To maximize the effectiveness of heat exchangers for recovering the waste heat, it is vital to select the most suitable working fluid for the system, not to mention that it is important to find the optimum design for the heat exchangers. The design of heat exchanger is out of scoop of this study; rather, the main focus has been on the right selection of working fluid for the co-generation system. Simulation study was carried out to find the most suitable working fluid that can allow the system to achieve the optimum efficiency in terms of the heat recovery rate and thermal efficiency.

Keywords: Cycle Analysis, Heat Recovery, Rankine Cycle, Waste Heat Recovery, Working Fluid.

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Authors: Shakil A. Kagzi, Sanjay Patil, Harit K. Raval

Abstract:

Tailor Welded Blanks (TWB) are utilized in automotive industries widely because of their advantage of weight and cost reduction and maintaining required strength and structural integrity. TWB consist of two or more sheet having dissimilar or similar material and thickness; welded together to form a single sheet before forming it to desired shape. Forming of the tailor welded blank is affected by ratio of thickness of blanks, ratio of their strength, etc. mainly due to in-homogeneity of material. In the present work the relative effect of these parameters on weld line movement is studied during deep drawing of TWB using FE simulation using HYPERWORKS. The simulation is validated with results from the literature. Simulations were than performed based on Taguchi orthogonal array followed by the ANOVA analysis to determine the significance of these parameters on forming of TWB.

Keywords: ANOVA, Deep drawing, Tailor Welded Blank, TWB, Weld line movement.

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Authors: M. Seidl, J. Bobek, P. Lenfeld, L. Běhálek, A. Ausperger

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This paper deals with the evaluation of flow properties of polymeric matrix with natural animal fillers. Technical university of Liberec cooperates on the long-term development of “green materials“ that should replace conventionally used materials (especially in automotive industry). Natural fibres (of animal and plant origin) from all over the world are collected and adapted (drying, cutting etc.) for extrusion processing. Inside the extruder these natural additives are blended with polymeric (synthetic and biodegradable - PLA) matrix and created compound is subsequently cut for pellets in the wet way. These green materials with unique recipes are then studied and their mechanical, physical and processing properties are determined. The main goal of this research is to develop new ecological materials very similar to unfilled polymers. In this article the rheological behaviour of chosen natural animal fibres is introduced considering their shape and surface that were observed with use of SEM microscopy.

Keywords: Polypropylene matrix, Green polymers, Rheology, Natural animal fibres.

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Authors: Zeynep Parlar, Şengül Ari, Rıfat Yilmaz, Erdem Özdemir, Arda Kahraman

Abstract:

New regulations and standards for noise emission increasingly compel the automotive firms to make some improvements about decreasing the engine noise. Nowadays, the perforated reactive mufflers which have an effective damping capability are specifically used for this purpose. New designs should be analyzed with respect to both acoustics and back pressure. In this study, a reactive perforated muffler is investigated numerically and experimentally. For an acoustical analysis, the transmission loss which is independent of sound source of the present cross flow, the perforated muffler was analyzed by COMSOL. To be able to validate the numerical results, transmission loss was measured experimentally. Back pressure was obtained based on the flow field analysis and was also compared with experimental results. Numerical results have an approximate error of 20% compared to experimental results.

Keywords: Back Pressure, Perforated Muffler, Transmission Loss.

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Authors: Byeong-Sam Kim, Kangsu Lee, Kyoungwoo Park, Samir Ben Chaabane

Abstract:

A Vehicle-s door wireing harness arrangement structure is provided. In vehicle-s door wiring harness(W/H) system is more toward to arrange a passenger compartment than a hinge and a weatherstrip. This article gives some insight into the dimensioning process, with special focus on large deflection analysis of wiring harness(W/H) in vehicle-s door structures for durability problem. An Finite elements analysis for door wiring harness(W/H) are used for residual stresses and dimensional stability with bending flexible. Durability test data for slim test specimens were compared with the numerical predicted fatigue life for verification. The final lifing of the component combines the effects of these microstructural features with the complex stress state arising from the combined service loading and residual stresses.

Keywords: Large deflection, wiring harness system, finite element analysis, vehicle's door.

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Authors: Mohamed Essahafi, Mustapha Ait Lafkih

Abstract:

In industrial environments, the heat exchanger is a necessary component to any strategy of energy conversion. Much of thermal energy used in industrial processes passes at least one times by a heat exchanger, and methods systems recovering thermal energy. This survey paper tries to presents in a systemic way an sample control of a heat exchanger by comparison between three controllers LQR (linear quadratic regulator), PID (proportional, integrator and derivate) and Pole Placement. All of these controllers are used mainly in industrial sectors (chemicals, petrochemicals, steel, food processing, energy production, etc…) of transportation (automotive, aeronautics), but also in the residential sector and tertiary (heating, air conditioning, etc...) The choice of a heat exchanger, for a given application depends on many parameters: field temperature and pressure of fluids, and physical properties of aggressive fluids, maintenance and space. It is clear that the fact of having an exchanger appropriate, well-sized, well made and well used allows gain efficiency and energy processes.

Keywords: LQR linear-quadratic regulator, PID control, Pole Placement, Heat exchanger.

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Authors: S. Onoda, S. Yoshihara, B. J. MacDonald, Y. Okude

Abstract:

Aluminum alloy sheets have several advantages such as the lightweight, high-specific strength and recycling efficiency. Therefore, aluminum alloy sheets in sheet forming have been used in various areas as automotive components and so forth. During the process of sheet forming, wrinkling which is caused by compression stress might occur and the formability of sheets was affected by occurrence of wrinkling. A few studies of uniaxial compressive test by using square tubes, pipes and sheets were carried out to clarify the each wrinkling behavior. However, on uniaxial compressive test, deformation behavior of the sheets hasn-t be cleared. Then, it is necessary to clarify the relationship between the buckling behavior and the forming conditions. In this study, the effect of dimension of the sheet in the buckling behavior on compression test of aluminum alloy sheet was cleared by experiment and FEA. As the results, the buckling deformation was classified by three modes in terms of the distribution of equivalent plastic strain.

Keywords: Sheet forming, Compression test, Aluminum alloy sheet, Buckling behavior

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Authors: C. Guven, M. Tufekci, E. Bayik, O. Gedik, M. Tas

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A sliding door system is used in commercial vehicles and passenger cars to allow a larger unobstructed access to the interior for loading and unloading. The movement of a sliding door on vehicle body is ensured by mechanisms and tracks having special cross-section which is manufactured by roll forming and stretch bending process. There are three tracks and three mechanisms which are called upper, central and lower on a sliding door system. There are static requirements as strength on different directions, rigidity for mechanisms, door drop off, door sag; dynamic requirements as high energy slam opening-closing and durability requirement to validate these products. In addition, there is a kinematic requirement to find out force values from door handle during manual operating. In this study, finite element analysis and physical test results which are realized for sliding door systems will be shared comparatively.

Keywords: Finite element analysis, sliding door, experimental, verification, vehicle tests.

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Authors: A. Khebli, S. Aguib, Y. Kateb, L. Guenfoud, N. Chikh, M. Tourab, T. Djedid, W. Dilmi, A. Hadidi, H. Meglouli

Abstract:

Composite structures based on magnetorheological elastomers (MREs) are widely used in many industrial sectors, such as automotive, naval, railway, aeronautical, aerospace, and building industries because of their adjustable mechanical properties by an external stimulus. In this work, experimental tests and numerical simulations carried out have shown that the use of these new structures, developed from honeycomb core, and MRE with aluminum skins, make it possible to improve particularly the overall rigidity and to reduce the vibration amplitudes. The results found showed that these hybrid structures have a very good mechanical resistance due mainly to the honeycomb core, and a very good shock absorber due mainly to the core of the MRE. The elaborated composite structure is intended to be used in industrial sectors subject to great efforts and a high amplitude of vibration such as helicopter wings and air turbines.

Keywords: Hybrid sandwich structures, magnetorheological elastomer, honeycomb, 3-point bending, mechanical strength.

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Authors: S. F. Wong, S. S. Dol

Abstract:

Automotive designers have been trying to use dimples to reduce drag in vehicles. In this work, a car model has been applied with dimple surface with a parameter called dimple ratio DR, the ratio between the depths of the half dimple over the print diameter of the dimple, has been introduced and numerically simulated via k-ε turbulence model to study the aerodynamics performance with the increasing depth of the dimples The Ahmed body car model with 25 degree slant angle is simulated with the DR of 0.05, 0.2, 0.3 0.4 and 0.5 at Reynolds number of 176387 based on the frontal area of the car model. The geometry of dimple changes the kinematics and dynamics of flow. Complex interaction between the turbulent fluctuating flow and the mean flow escalates the turbulence quantities. The maximum level of turbulent kinetic energy occurs at DR = 0.4. It can be concluded that the dimples have generated extra turbulence energy at the surface and as a result, the application of dimples manages to reduce the drag coefficient of the car model compared to the model with smooth surface.

Keywords: Aerodynamics, Boundary Layer, Dimple, Drag, Kinetic Energy, Turbulence.

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Authors: K. Shahril, A. Nizam, M. Sabri, A. Siti Rohana, H. Salmah

Abstract:

Chemical modifier (Acrylic Acid) is used as filler treatment to improve mechanical properties and swelling behavior of polypropylene/coconut fiber (PP/CF) composites by creating more adherent bonding between CF filler and PP Matrix. Treated (with chemical modifier) and untreated (without chemical modifier) composites were prepared in the formulation of 10 wt%, 20 wt%, 30 wt%, and 40 wt%. The mechanical testing indicates that composite with 10 wt% of untreated composite has the optimum value of tensile strength, and the composite with chemical modifier shows the tensile strength was increased. By increasing of filler loading, elastic modulus was increased while the elongation at brake was decreased. Meanwhile, the swelling test discerned that the increase of filler loading increased the water absorption of composites and the presence of chemical modifier reduced the equilibrium water absorption percentage.

Keywords: Coconut fiber, polypropylene, acid acrylic, ethanol, chemical modifier, composites.

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Authors: Watcharapan Sukkerd, Teeradej Wuttipornpun

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This paper aims to present non-population search algorithms called tabu search (TS), simulated annealing (SA) and variable neighborhood search (VNS) to minimize the total cost of capacitated MRP problem in multi-stage assembly flow shop with two alternative machines. There are three main steps for the algorithm. Firstly, an initial sequence of orders is constructed by a simple due date-based dispatching rule. Secondly, the sequence of orders is repeatedly improved to reduce the total cost by applying TS, SA and VNS separately. Finally, the total cost is further reduced by optimizing the start time of each operation using the linear programming (LP) model. Parameters of the algorithm are tuned by using real data from automotive companies. The result shows that VNS significantly outperforms TS, SA and the existing algorithm.

Keywords: Capacitated MRP, non-population search algorithms, linear programming, assembly flow shop.

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Authors: D. Reich, R. Stark

Abstract:

To provide reliable and valid findings when evaluating innovative in-car devices in the automotive context highly realistic driving environments are recommended. Nowadays, in-car devices are mostly evaluated due to driving simulator studies followed by real car driving experiments. Driving simulators are characterized by high internal validity, but weak regarding ecological validity. Real car driving experiments are ecologically valid, but difficult to standardize, more time-robbing and costly. One economizing suggestion is to implement more immersive driving environments when applying driving simulator studies. This paper presents research comparing non-immersive standard PC conditions with mobile and highly immersive Oculus Rift conditions while performing the Lane Change Task (LCT). Subjective data with twenty participants show advantages regarding presence and immersion experience when performing the LCT with the Oculus Rift, but affect adversely cognitive workload and simulator sickness, compared to non-immersive PC condition.

Keywords: LCT, immersion, oculus rift, presence, situation awareness.

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Authors: Mostafa Makrahy, Nouby Ghazaly, Ahmad Moaaz

Abstract:

Brakes are one of the most important safety and performance components in automobiles and airplanes. Development of brakes has mainly focused on increasing braking power and stability. Nowadays, brake noise, vibration and harshness (NVH) together with brake dust emission and pad life are very important to vehicle drivers. The main objective of this research is to define the relationship between compressibility of friction materials and their tendency to generate vibration. An experimental study of the friction-induced vibration obtained by the disc brake system of a passenger car is conducted. Three commercial brake pad materials from different manufacturers are tested and evaluated under various brake conditions against cast iron disc brake. First of all, compressibility test for the brake friction material are measured for each pad. Then, brake dynamometer is used to simulate and reproduce actual vehicle braking conditions. Finally, a comparison between the three pad specimens is conducted. The results showed that compressibility have a very significant effect on reduction the vibration occurrence.

Keywords: Automotive brake, friction material, brake dynamometer, compressibility test.

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Authors: K. Kalaiselvan, A. Elango, N. M. Nagarajan

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Laser beam welding for the dissimilar Titanium and Aluminium thin sheets is an emerging area which is having wider applications in aerospace, aircraft, automotive, electronics and in other industries due to its high speed, non-contact, precision with low heat effects, least welding distortion, low labor costs and convenient operation. Laser beam welding of dissimilar metal combinations are increasingly demanded due to high energy densities with small fusion and heat affected zones. Furthermore, no filler or electrode material is required and contamination of weld is also very small. The present study is to reviews the influence of different parameters like laser power, welding speed, power density, beam diameter, focusing distance and type of shielding gas on the mechanical properties of dissimilar metal combinations like SS/Al, Cu/Al and Ti/Al focusing on aluminum to other materials. Research findings reveal that Ti/Al combination gives better metallurgical and mechanical properties than other combinations such as SS/Al and Cu/Al.

Keywords: Laser Beam Welding, dissimilar metals, SS/Al, Cu/Al and Ti/Al sheets.

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Authors: Masato Nishi, Tetsushi Kaburagi, Masashi Kurose, Tei Hirashima, Tetsusei Kurasiki

Abstract:

The process of thermoforming a carbon fiber reinforced thermoplastic (CFRTP) has increased its presence in the automotive industry for its wide applicability to the mass production car. A non-isothermal forming for CFRTP can shorten its cycle time to less than 1 minute. In this paper, the textile reinforcement FE model which the authors proposed in a previous work is extended to the CFRTP model for non-isothermal forming simulation. The effect of thermoplastic is given by adding shell elements which consider thermal effect to the textile reinforcement model. By applying Reuss model to the stress calculation of thermoplastic, the proposed model can accurately predict in-plane shear behavior, which is the key deformation mode during forming, in the range of the process temperature. Using the proposed model, thermoforming simulation was conducted and the results are in good agreement with the experimental results.

Keywords: Carbon fiber reinforced thermoplastic (CFRTP), Finite element analysis (FEA), Pre-impregnated textile composite, Non-isothermal forming.

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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

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Authors: M. M. M. Salem, Ayman A. Aly

Abstract:

An active suspension system has been proposed to improve the ride comfort. A quarter-car 2 degree-of-freedom (DOF) system is designed and constructed on the basis of the concept of a four-wheel independent suspension to simulate the actions of an active vehicle suspension system. The purpose of a suspension system is to support the vehicle body and increase ride comfort. The aim of the work described in the paper was to illustrate the application of fuzzy logic technique to the control of a continuously damping automotive suspension system. The ride comfort is improved by means of the reduction of the body acceleration caused by the car body when road disturbances from smooth road and real road roughness. The paper describes also the model and controller used in the study and discusses the vehicle response results obtained from a range of road input simulations. In the conclusion, a comparison of active suspension fuzzy control and Proportional Integration derivative (PID) control is shown using MATLAB simulations.

Keywords: Fuzzy logic control, ride comfort, vehicle dynamics, active suspension system, quarter-car model.

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Authors: M. Chandrasekaran, D. Devarasiddappa

Abstract:

Metal matrix composites have been increasingly used as materials for components in automotive and aerospace industries because of their improved properties compared with non-reinforced alloys. During machining the selection of appropriate machining parameters to produce job for desired surface roughness is of great concern considering the economy of manufacturing process. In this study, a surface roughness prediction model using fuzzy logic is developed for end milling of Al-SiCp metal matrix composite component using carbide end mill cutter. The surface roughness is modeled as a function of spindle speed (N), feed rate (f), depth of cut (d) and the SiCp percentage (S). The predicted values surface roughness is compared with experimental result. The model predicts average percentage error as 4.56% and mean square error as 0.0729. It is observed that surface roughness is most influenced by feed rate, spindle speed and SiC percentage. Depth of cut has least influence.

Keywords: End milling, fuzzy logic, metal matrix composites, surface roughness

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Authors: Kuen-Long Leu, Yung-Yuan Chen, Chin-Long Wey, Jwu-E Chen, Chung-Hsien Hsu

Abstract:

The increasing importance of FlexRay systems in automotive domain inspires unceasingly relative researches. One primary issue among researches is to verify the reliability of FlexRay systems either from protocol aspect or from system design aspect. However, research rarely discusses the effect of network topology on the system reliability. In this paper, we will illustrate how to model the reliability of FlexRay systems with various network topologies by a well-known probabilistic reasoning technology, Bayesian Network. In this illustration, we especially investigate the effectiveness of error containment built in star topology and fault-tolerant midpoint synchronization algorithm adopted in FlexRay communication protocol. Through a FlexRay steer-by-wire case study, the influence of different topologies on the failure probability of the FlexRay steerby- wire system is demonstrated. The notable value of this research is to show that the Bayesian Network inference is a powerful and feasible method for the reliability assessment of FlexRay systems.

Keywords: Bayesian Network, FlexRay, fault tolerance, network topology, reliability.

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Authors: Gia Surguladze, Lily Petriashvili, Nino Topuria, Giorgi Surguladze

Abstract:

Modelling of building processes of a multimodal freight transportation support information system is discussed based on modern CASE technologies. Functional efficiencies of ports in the eastern part of the Black Sea are analyzed taking into account their ecological, seasonal, resource usage parameters. By resources, we mean capacities of berths, cranes, automotive transport, as well as work crews and neighbouring airports. For the purpose of designing database of computer support system for Managerial (Logistics) function, using Object-Role Modeling (ORM) tool (NORMA–Natural ORM Architecture) is proposed, after which Entity Relationship Model (ERM) is generated in automated process. Software is developed based on Process-Oriented and Service-Oriented architecture, in Visual Studio.NET environment.

Keywords: Seaport resources, business-processes, multimodal transportation, CASE technology, object-role model, entity relationship model, SOA.

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Authors: M. Fette, J. P. Wulfsberg, A. Herrmann, R.-H. Ladstaetter

Abstract:

Lightweight design represents an important key to successful implementation of energy-saving, fuel-efficient and environmentally friendly means of transport in the aerospace and automotive industry. In this context the use of carbon fibre reinforced plastics (CFRP) which are distinguished by their outstanding mechanical properties at relatively low weight, promise significant improvements. Due to the reduction of the total mass, with the resulting lowered fuel or energy consumption and CO2 emissions during the operational phase, commercial aircraft will increasingly be made of CFRP. An auspicious technology for the efficient and economic production of high performance thermoset composites and hybrid structures for future lightweight applications is the combination of carbon fibre sheet moulding compound, tailored continuous carbon fibre reinforcements and metallic components in a one-shot pressing and curing process. This paper deals with a hybrid composite technology for aerospace industries, which was developed with the help of a special innovation and development system.

Keywords: Composite, development, hybrid, innovation, system.

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Authors: Devdutt, M. L. Aggarwal

Abstract:

The development of vehicles having best ride comfort and safety of travelling passengers is of great interest for automotive manufacturers. The effect of transmitted vibrations from car body to passenger seat is required to be controlled for achieving the same. The application of magneto-rheological (MR) shock absorber in suspension system has been considered to achieve significant benefits in this regard. This paper introduces a secondary suspension controlled semi-active quarter car system using MR shock absorber for effective vibration control. Fuzzy logic control system is used for design of controller for actual damping force generation by MR shock absorber. Performance evaluations are done related to passenger seat acceleration and displacement in time and frequency domains, in order to see the effectiveness of the proposed semi-active suspension system. Simulation results show that the semi-active suspension system provides better results compared to passive suspension system in terms of passenger ride comfort improvement.

Keywords: Fuzzy logic control, MR shock absorber, Quarter car model, Semi-active suspension system.

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

Abstract:

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

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

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Authors: A. R. Ismail, N. Jusoh, M. Z. Nuawi, B. M. Deros, N. K. Makhtar, M. N. A. Rahman

Abstract:

The objective of this study is to determine the thermal comfort among worker at Malaysian automotive industry. One critical manual assembly workstation had been chosen as a subject for the study. The human subjects for the study constitute operators at Body Assembly Station of the factory. The environment examined was the Relative Humidity (%), Airflow (m/s), Air Temperature (°C) and Radiant Temperature (°C) of the surrounding workstation area. The environmental factors were measured using Babuc apparatus, which is capable to measure simultaneously those mentioned environmental factors. The time series data of fluctuating level of factors were plotted to identify the significant changes of factors. Then thermal comfort of the workers were assessed by using ISO Standard 7730 Thermal sensation scale by using Predicted Mean Vote (PMV). Further Predicted percentage dissatisfied (PPD) is used to estimate the thermal comfort satisfaction of the occupant. Finally the PPD versus PMV were plotted to present the thermal comfort scenario of workers involved in related workstation. The result of PMV at the related industry is between 1.8 and 2.3, where PPD at that building is between 60% to 84%. The survey result indicated that the temperature more influenced comfort to the occupants

Keywords: Thermal, Comfort, Temperature, PPD, PMV

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Authors: Liu Ying-jie, Lu Wen-bo, Peng Cheng-jian

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With the development of the automotive technology and electric vehicle, the contribution of the wind noise on the interior noise becomes the main source of noise. The main transfer path which the exterior excitation is transmitted through is the greenhouse panels and side windows. Simulating the wind noise transmitted into the vehicle accurately in the early development stage can be very challenging. The basic methodologies of this study were based on the Lighthill analogy; the exterior flow field around a passenger car was computed using unsteady Computational Fluid Dynamics (CFD) firstly and then a Finite Element Method (FEM) was used to compute the interior acoustic response. The major findings of this study include: 1) The Sound Pressure Level (SPL) response at driver’s ear locations is mainly induced by the turbulence pressure fluctuation; 2) Peaks were found over the full frequency range. It is found that the methodology used in this study could predict the interior wind noise induced by the exterior aerodynamic excitation in industry.

Keywords: Wind noise, computational fluid dynamics, finite element method, passenger car.

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