Search results for: Flexible Manufacturing

Authors: Diana Flores Galindo, Richard Gil Herrera

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Nowadays, Lean Manufacturing and Industry 4.0 are very important in every country. One of the main benefits is continued market presence. It has been identified that there is a need to change existing educational programs, as well as update the knowledge and skills of existing employees. It should be borne in mind that behind each technological improvement, there is a human being. Human talent cannot be neglected. The main objectives of this article are to review the link between Lean Manufacturing, the incorporation of Industry 4.0 and the steps to follow to implement it; analyze the current situation and study the implications and benefits of this new trend, with a particular focus on Mexico. Lean Manufacturing and Industry 4.0 implementation waves must always take care of the most important capital – intellectual capital. The methodology used in this article comprised the following steps: reviewing the reality of the fourth industrial revolution, reviewing employees’ skills on the journey to become world-class, and analyzing the situation in Mexico. Lean Manufacturing and Industry 4.0 were studied not as exclusive concepts, but as complementary ones. The methodological framework used is focused on motivating companies’ collaborators to guarantee common results, innovate, and remain in the market in the face of new requirements from company stakeholders. The key findings were that both trends emphasize the need to improve communication across the entire company and incorporate new technologies into everyday work, from the shop floor to administrative staff, to help improve processes. Taking care of people, activities and processes will bring a company success. In the specific case of Mexico, companies in all sectors need to be aware of and implement technological improvements according to their specific needs. Low-cost labor represents one of the most typical barriers. In conclusion, companies must build a roadmap according to their strategy and needs to achieve their short, medium- and long-term goals.

Keywords: Lean management, lean manufacturing, industry 4.0, motivation, SWOT analysis, Hoshin Kanri.

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Authors: Hanieh Jalali, Ahmad Baraani

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Nowaday-s, many organizations use systems that support business process as a whole or partially. However, in some application domains, like software development and health care processes, a normative Process Aware System (PAS) is not suitable, because a flexible support is needed to respond rapidly to new process models. On the other hand, a flexible Process Aware System may be vulnerable to undesirable and fraudulent executions, which imposes a tradeoff between flexibility and security. In order to make this tradeoff available, a genetic-based anomaly detection model for logs of Process Aware Systems is presented in this paper. The detection of an anomalous trace is based on discovering an appropriate process model by using genetic process mining and detecting traces that do not fit the appropriate model as anomalous trace; therefore, when used in PAS, this model is an automated solution that can support coexistence of flexibility and security.

Keywords: Anomaly Detection, Genetic Algorithm, ProcessAware Systems, Process Mining.

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Authors: A.V.Naresh Babu, S.Sivanagaraju, Ch.Padmanabharaju, T.Ramana

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The interline power flow controller (IPFC) is one of the latest generation flexible AC transmission systems (FACTS) controller used to control power flows of multiple transmission lines. This paper presents a mathematical model of IPFC, termed as power injection model (PIM). This model is incorporated in Newton- Raphson (NR) power flow algorithm to study the power flow control in transmission lines in which IPFC is placed. A program in MATLAB has been written in order to extend conventional NR algorithm based on this model. Numerical results are carried out on a standard 2 machine 5 bus system. The results without and with IPFC are compared in terms of voltages, active and reactive power flows to demonstrate the performance of the IPFC model.

Keywords: flexible AC transmission systems (FACTS), interline power flow controller (IPFC), power injection model (PIM), power flow control.

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Authors: Kwan Hee Han, Jun Woo Park, Seock Kyu Yoo, Geon Lee

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As business environments are rapidly changing, the manufacturing system must be reconfigured to adapt to various customer needs. In order to cope with this challenge, it is quintessential to test industrial control logic rapidly and easily in the design time, and monitor operational behavior in the run time of automated manufacturing system. Proposed integrated model for virtual prototyping and operational monitoring of industrial control logic is to improve limitations of current ladder programming practices and general discrete event simulation method. Each plant layout model using HMI package and object-oriented control logic model is designed independently and is executed simultaneously in integrated manner to reflect design practices of automation system in the design time. Control logic is designed and executed using UML activity diagram without considering complicated control behavior to deal with current trend of reconfigurable manufacturing. After the physical installation, layout model of virtual prototype constructed in the design time is reused for operational monitoring of system behavior during run time.

Keywords: automated manufacturing system, HMI, monitoring, object-oriented, PLC, virtual prototyping

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Authors: Ilham Benali, Nasser Hajji, Nawfal Acha

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Given the fact that the pharmaceutical industry is a commonly studied sector in the context of innovation, the majority of innovation research is devoted to the developed markets known by high research and development (R&D) assets and intensive innovation. In contrast, in developing countries where R&D assets are very low, there is relatively little research to mention in the area of pharmaceutical sector innovation, characterized mainly by two principal elements which are the presence of foreign-owned firms and licensed manufacturing agreements between local firms and multinationals. With the scarcity of research in this field, this paper attempts to study the effect of these two elements on the firms’ innovation tendencies. Other traditional factors that influence innovation, which are the age and the size of the firm, the R&D activities and the market structure, revealed in the literature review, will be included in the study in order to try to make this work more exhaustive. The study starts by examining innovation tendency in pharmaceutical firms located in developing countries before analyzing the effect of foreign-owned firms and licensed manufacturing agreements between local firms and multinationals on technological, organizational and marketing innovation. Based on the related work and on the theoretical framework developed, there is a probability that foreign-owned firms and licensed manufacturing agreements between local firms and multinationals have a negative influence on technological innovation. The opposite effect is possible in the case of organizational and marketing innovation.

Keywords: Developing countries, foreign owned firms, innovation, licensed manufacturing agreements, pharmaceutical industry.

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Authors: Yuan-Jye Tseng, Yi-Shiuan Chen

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In this paper, a new concept of closed-loop design for a product is presented. The closed-loop design model is developed by integrating forward design and reverse design. Based on this new concept, a closed-loop design model for sustainable manufacturing by integrated evaluation of forward design, reverse design, and green manufacturing using a fuzzy analytic network process is developed. In the design stage of a product, with a given product requirement and objective, there can be different ways to design the detailed components and specifications. Therefore, there can be different design cases to achieve the same product requirement and objective. Subsequently, in the design evaluation stage, it is required to analyze and evaluate the different design cases. The purpose of this research is to develop a model for evaluating the design cases by integrated evaluating the criteria in forward design, reverse design, and green manufacturing. A fuzzy analytic network process method is presented for integrated evaluation of the criteria in the three models. The comparison matrices for evaluating the criteria in the three groups are established. The total relational values among the three groups represent the total relational effects. In applications, a super matrix model is created and the total relational values can be used to evaluate the design cases for decision-making to select the final design case. An example product is demonstrated in this presentation. It shows that the model is useful for integrated evaluation of forward design, reverse design, and green manufacturing to achieve a closed-loop design for sustainable manufacturing objective.

Keywords: Design evaluation, forward design, reverse design, closed-loop design, supply chain management, closed-loop supply chain, fuzzy analytic network process.

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Authors: Gregor Radonjič, Aleksandra P. Korda, Damijan Krajnc

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The aim of the study was to investigate whether there is the promotion of product ecodesign measures as a result of adopting ISO 14001 certification in manufacturing companies in the Republic of Slovenia. Companies gave the most of their product development attention to waste and energy reduction during manufacturing process and reduction of material consumption per unit of product. Regarding the importance of different ecodesign criteria reduction of material consumption per unit of product was reported as the most important criterion. Less attention is paid to endof- life issues considering recycling or packaging. Most manufacturing enterprises considered ISO 14001 standard as a very useful tool or at least a useful tool helping them to accelerate and establish product ecodesign activities. Two most frequently considered ecodesign drivers are increased competitive advantage and legal requirements and two most important barriers are high development costs and insufficient market demand.

Keywords: ecodesign, environmental management system, ISO 14001, products

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Authors: Jae-Min Yu, Hyoung-Ho Doh, Ji-Su Kim, Dong-Ho Lee, Sung-Ho Nam

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A reconfigurable manufacturing system (RMS) is an advanced system designed at the outset for rapid changes in its hardware and software components in order to quickly adjust its production capacity and functionally. Among various operational decisions, this study considers the scheduling problem that determines the input sequence and schedule at the same time for a given set of parts. In particular, we consider the practical constraints that the numbers of pallets/fixtures are limited and hence a part can be released into the system only when the fixture required for the part is available. To solve the integrated input sequencing and scheduling problems, we suggest a priority rule based approach in which the two sub-problems are solved using a combination of priority rules. To show the effectiveness of various rule combinations, a simulation experiment was done on the data for a real RMS, and the test results are reported.

Keywords: Reconfigurable manufacturing system, scheduling, priority rules, multiple process plans, pallets/fixtures

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Authors: Wadea Ameen, Abdulrahman Al-Ahmari, Osama Abdulhameed

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Electron beam melting (EBM) is one of the modern additive manufacturing (AM) technologies. In EBM, the electron beam melts metal powder into a fully solid part layer by layer. Since EBM is a new technology, most designers are unaware of the capabilities and the limitations of EBM technology. Also, many engineers are facing many challenges to utilize the technology because of a lack of design rules for the technology. The aim of this study is to identify the capabilities and the limitations of EBM technology in fabrication of small features and overhang structures and develop a design rules that need to be considered by designers and engineers. In order to achieve this objective, a series of experiments are conducted. Several features having varying sizes were designed, fabricated, and evaluated to determine their manufacturability limits. In general, the results showed the capabilities and limitations of the EBM technology in fabrication of the small size features and the overhang structures. In the end, the results of these investigation experiments are used to develop design rules. Also, the results showed the importance of developing design rules for AM technologies in increasing the utilization of these technologies.

Keywords: Additive manufacturing, design for additive manufacturing, electron beam melting, self-supporting overhang.

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Authors: Ružarovský, Roman, Danišová, Nina, Velíšek, Karol

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In this contribution is presented a complex design of individual objects identification in the workplace of intelligent assembly cell. Intelligent assembly cell is situated at Institute of Manufacturing Systems and Applied Mechanics and is used for pneumatic actuator assembly. Pneumatic actuator components are pneumatic roller, cover, piston and spring. Two identification objects alternatives for assembly are designed in the workplace of industrial robot. In the contribution is evaluated and selected suitable alternative for identification – 2D codes reader. The complex design of individual object identification is going out of intelligent manufacturing systems knowledge. Intelligent assembly and manufacturing systems as systems of new generation are gradually loaded in to the mechanical production, when they are removeing human operation out of production process and they also short production times.

Keywords: system, cell, intelligent, mechanics, device

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Authors: Raja Kannusamy

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The research focuses on the applicable technologies in the automobile industry and their effects on the productivity and annual revenue of the industry. A study has been conducted on six major automobile manufacturing industries represented in this research as M1, M2, M3, M4, M5 and M6. The results indicate that M1, which is a pioneer in technological applications, remains the market leader, followed by M5 and M2 taking the second and third positions, respectively. M3, M6 and M4 are the followers and are placed next in positions. It has also been observed that M1 and M2 have entered into an agreement to share the basic structural technologies and they maintain long-term and trusted relationships with their suppliers through the Keiretsu system. With technological giants such as Apple, Microsoft, Uber and Google entering the automobile industry in recent years, an upward trend is expected in the futuristic market with self-driving cars to dominate the automobile sector. To keep up with the market trend, it is essential for automobile manufacturers to understand the importance of developing technological capabilities and skills to be competitive in the marketplace.

Keywords: automobile manufacturing industries, competitiveness, performance improvement, technological applications

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Authors: S.P.Gautam, P.S.Bundela, R.K. Jain, V. N. Tripathi

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The manufacturing transmission line tower parts has being generated hazardous waste which is required proper disposal of waste for protection of land pollution. Manufacturing Process in the manufacturing of steel angle, plates, pipes, channels are passes through conventional, semi automatic and CNC machines for cutting, marking, punching, drilling, notching, bending operations. All fabricated material Coated with thin layer of Zinc in Galvanizing plant where molten zinc is used for coating. Prior to Galvanizing, chemical like 33% concentrated HCl Acid, ammonium chloride and d-oil being used for pretreatment of iron. The bath of water with sodium dichromate is used for cooling and protection of the galvanized steel. For the heating purpose the furnace oil burners are used. These above process the Zinc dross, Zinc ash, ETP sludge and waste pickled acid generated as hazardous waste. The RPG has made captive secured land fill site, since 1997 since then it was using for disposal of hazardous waste after completion of SLF (Secured land fill) site. The RPG has raised height from ground level then now it is being used for disposal of waste as he designed the SLF after in creasing height of from GL it is functional without leach ate or adverse impacts in the environment.

Keywords: Disposal, Drilling, Fabricated. Hazardous waste, Punching.

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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.

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Authors: Jessada Monthasuwan, Charinsak Saetiaw, Chanchai Thongsopa

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This paper presents the development and design of the curved rectangular patch arrays antenna for small missile application. This design uses a 0.1mm flexible copper sheet on the front layer and back layer, and a 1.8mm PVC substrate on a middle layer. The study used a small missile model with 122mm diameter size with speed 1.1 Mach and frequency range on ISM 2.4 GHz. The design of curved antenna can be installation on a cylindrical object like a missile. So, our proposed antenna design will have a small size, lightweight, low cost and simple structure. The antenna was design and analysis by a simulation result from CST microwave studio and confirmed with a measurement result from a prototype antenna. The proposed antenna has a bandwidth covering the frequency range 2.35-2.48 GHz, the return loss below -10 dB and antenna gain 6.5 dB. The proposed antenna can be applied with a small guided missile effectively.

Keywords: Rectangular path arrays, small missile antenna.

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Authors: Jeff Letcher, Dennis Tierney, Haider Raad

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Antennas are devices for transmitting and/or receiving signals which make them a necessary component of any wireless system. In this paper, a thermal deposition technique is utilized as a method to fabricate antenna structures on substrates. Thin-film deposition is achieved by evaporating a source material (metals in our case) in a vacuum which allows vapor particles to travel directly to the target substrate which is encased with a mask that outlines the desired structure. The material then condenses back to solid state. This method is used in comparison to screen printing, chemical etching, and ink jet printing to indicate advantages and disadvantages to the method. The antenna created undergoes various testing of frequency ranges, conductivity, and a series of flexing to indicate the effectiveness of the thermal deposition technique. A single band antenna that is operated at 2.45 GHz intended for wearable and flexible applications was successfully fabricated through this method and tested. It is concluded that thermal deposition presents a feasible technique of producing such antennas.

Keywords: Thermal deposition, wearable antennas, Bluetooth technology, flexible electronics.

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Authors: Md Rashadul Islam, Mesbah U. Ahmed, Rafiqul A. Tarefder

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This study evaluates the back calculation of stiffness of a pavement section on Interstate 40 (I-40)in New Mexico through numerical analysis. Falling Weight Deflectometer (FWD) test has been conducted on a section on I-40. Layer stiffness of the pavement has been backcalculated by a backcalculation software, ELMOD, using the FWD test data. Commercial finite element software, ABAQUS, has been used to develop the Finite Element Model (FEM) of this pavement section. Geometry and layer thickness are collected from field coring. Input parameters i.e. stiffnesses of different layers of the pavement are used as the backcalculated ones. Resulting surface deflections at different radial distances from the FEM analysis are compared with field FWD deflection values. It shows close agreement between the FEM and FWD outputs. Therefore, the FWD test method can be considered to be a reliable test procedure for evaluating the in situ stiffness of pavement material.

Keywords: Falling weight deflectometer test, Finite element model, Flexible pavement, moduli, surface deflection.

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Authors: Vinod B. Suryawanshi, Ajit D. Kelkar

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Composite materials, due to their unique properties such as high strength to weight ratio, corrosion resistance, and impact resistance have huge potential as structural materials in automotive, construction and transportation applications. However, these properties often come at higher cost owing to complex design methods, difficult manufacturing processes and raw material cost. Traditionally, tapered laminated composite structures are manufactured using autoclave manufacturing process by ply drop off technique. Autoclave manufacturing though very powerful suffers from high capital investment and higher energy consumption. As per the current trends in composite manufacturing, Out of Autoclave (OoA) processes are looked as emerging technologies for manufacturing the structural composite components for aerospace and defense applications. However, there is a need for improvement among these processes to make them reliable and consistent. In this paper, feasibility of using out of autoclave process to manufacture the variable thickness cantilever beam is discussed. The minimum weight design for the composite beam is obtained using constant stress beam concept by tailoring the thickness of the beam. Ply drop off techniques was used to fabricate the variable thickness beam from glass/epoxy prepregs. Experiments were conducted to measure bending stresses along the span of the cantilever beam at different intervals by applying the concentrated load at the free end. Experimental results showed that the stresses in the bean at different intervals were constant. This proves the ability of OoA process to manufacture the constant stress beam. Finite element model for the constant stress beam was developed using commercial finite element simulation software. It was observed that the simulation results agreed very well with the experimental results and thus validated design and manufacturing approach used.

Keywords: Beams, Composites, Constant Stress, Structures.

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Authors: Fernando Augusto Ullmann Tobe, Moacyr Amaral Domingues, Figueiredo, Stephany Rie Yamamoto Gushiken

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The purpose of this paper is to present the process of elaborating the layout of an assembly line of a welding industry using the principles of lean manufacturing as the main driver. The objective of this paper is relevant since the current layout of the assembly line causes non-productive times for operators, being related to the lean waste of unnecessary movements. The methodology used for the project development was Project-based Learning (PBL), which is an active way of learning focused on real problems. The process of selecting the methodology for layout planning was developed considering three criteria to evaluate the most relevant one for this paper's goal. As a result of this evaluation, Systematic Layout Planning was selected, and three steps were added to it – Value Stream Mapping for the current situation and after layout changed and the definition of lean tools and layout type. This inclusion was to consider lean manufacturing in the layout redesign of the industry. The layout change resulted in an increase in the value-adding time of operations carried out in the sector, reduction in movement times between previous and final assemblies, and in cost savings regarding the man-hour value of the employees, which can be invested in productive hours instead of movement times.

Keywords: Assembly line, layout, lean manufacturing, systematic layout planning.

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Authors: Sandhya, Rajbir Singh, Ramesh Kumar

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The purpose of this research paper on the subject of Leadership Effectiveness attempts to conduct a focused amount of research to examine the employees’ perceptions pertaining to specific competencies of leadership effectiveness in Indian manufacturing industries and to correlate their perceptions between private sectors and public sector undertakings. It specifically looks at the current definitions of leadership and looks at some historical background information relating to the more common theories that relate to leadership and effectiveness. This research was conducted by using a variety of current books and periodical articles on the topic of leadership effectiveness and employees’ perceptions. A number of leadership effectiveness competencies have been identified. The demographic details and perception of the employees on importance of leadership effectiveness competencies have been obtained through a well designed online questionnaire. For this purpose, a likert scale of seven-point has been used. Descriptive and inferential statistics is used to analyze the gathered data.

Keywords: Employees Perception, Leadership Effectiveness, Leadership Competencies, Manufacturing.

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Authors: M. Yosofi, S. Ezeddini, A. Ollivier, V. Lavaste, C. Mayousse

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Additive manufacturing processes have changed significantly in a wide range of industries and their application progressed from rapid prototyping to production of end-use products. However, their environmental impact is still a rather open question. In order to support the growth of this technology in the industrial sector, environmental aspects should be considered and predictive models may help monitor and reduce the environmental footprint of the processes. This work presents predictive models based on a previously developed methodology for the environmental impact evaluation combined with a technical and economical assessment. Here we applied the methodology to the Fused Deposition Modeling process. First, we present the predictive models relative to different types of machines. Then, we present a decision-making tool designed to identify the optimum manufacturing strategy regarding technical, economic, and environmental criteria.

Keywords: Additive manufacturing, decision-makings, environmental impact, predictive models.

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Authors: Lotfi Nabli, Achraf Jabeur Telmoudi, Radhi M'hiri

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This paper proposes a modeling method of the laws controlling manufacturing systems with temporal and non temporal constraints. A methodology of robust control construction generating the margins of passive and active robustness is being elaborated. Indeed, two paramount models are presented in this paper. The first utilizes the P-time Petri Nets which is used to manage the flow type disturbances. The second, the quality model, exploits the Intervals Constrained Petri Nets (ICPN) tool which allows the system to preserve its quality specificities. The redundancy of the robustness of the elementary parameters between passive and active is also used. The final model built allows the correlation of temporal and non temporal criteria by putting two paramount models in interaction. To do so, a set of definitions and theorems are employed and affirmed by applicator examples.

Keywords: Manufacturing systems control, flow, quality, robustness, redundancy, Petri Nets.

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Authors: Iqbalur Rahman, Miftahur Rahman, Abul L Haque, Mostafizur Rahman,

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In this paper, RSA encryption algorithm and its hardware implementation in Xilinx-s Virtex Field Programmable Gate Arrays (FPGA) is analyzed. The issues of scalability, flexible performance, and silicon efficiency for the hardware acceleration of public key crypto systems are being explored in the present work. Using techniques based on the interleaved math for exponentiation, the proposed RSA calculation architecture is compared to existing FPGA-based solutions for speed, FPGA utilization, and scalability. The paper covers the RSA encryption algorithm, interleaved multiplication, Miller Rabin algorithm for primality test, extended Euclidean math, basic FPGA technology, and the implementation details of the proposed RSA calculation architecture. Performance of several alternative hardware architectures is discussed and compared. Finally, conclusion is drawn, highlighting the advantages of a fully flexible & parameterized design.

Keywords: Crypto Accelerator, FPGA, Public Key Cryptography, RSA.

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Authors: P. Ahern, D. Collery

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The implementation of lean thinking in the manufacturing industry revolutionized the traditional approach to large-scale production through the process of identifying the waste in each task and putting in place mitigation measures to eliminate the waste in all its forms. The Irish construction industry, however, has been much slower to adopt the principles of lean, opting instead to stick with the traditional approach to construction project delivery which is inherently wasteful. Lean thinking holds the potential to revolutionize the construction industry in a similar manner to the adoption of lean manufacturing. Lean principles present opportunities for reduced project duration, reduced project cost, improved quality, and elimination of re-works and non-value-added activities. This research has been designed to accumulate research data through available literature, electronic surveys, and interviews. The results show an industry reluctant to accept change and an undefined path to successful lean construction implementation.

Keywords: Barriers, lean construction, lean implementation, lean manufacturing, lean philosophy.

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Authors: Myungraee Cha, Jun Seok Kim, Seung Hwan Park, Jun-Geol Baek

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In manufacturing industries, development of measurement leads to increase the number of monitoring variables and eventually the importance of multivariate control comes to the fore. Statistical process control (SPC) is one of the most widely used as multivariate control chart. Nevertheless, SPC is restricted to apply in processes because its assumption of data as following specific distribution. Unfortunately, process data are composed by the mixture of several processes and it is hard to estimate as one certain distribution. To alternative conventional SPC, therefore, nonparametric control chart come into the picture because of the strength of nonparametric control chart, the absence of parameter estimation. SVDD based control chart is one of the nonparametric control charts having the advantage of flexible control boundary. However,basic concept of SVDD has been an oversight to the important of data characteristic, density distribution. Therefore, we proposed DW-SVDD (Density Weighted SVDD) to cover up the weakness of conventional SVDD. DW-SVDD makes a new attempt to consider dense of data as introducing the notion of density Weight. We extend as control chart using new proposed SVDD and a simulation study of various distributional data is conducted to demonstrate the improvement of performance.

Keywords: Density estimation, Multivariate control chart, Oneclass classification, Support vector data description (SVDD)

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Authors: N. J. M. Yusof, T. Sabir, J. McLoughlin

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The garment manufacturing industry involves sequential processes that are subjected to uncontrollable variations. The industry depends on the skill of labour in handling the varieties of fabrics and accessories, machines, as well as complicated sewing operation. Due to these reasons, garment manufacturers have created systems to monitor and to control the quality of the products on a regular basis by conducting quality approaches to minimize variation. With that, the aim of this research has been to ascertain the quality approaches deployed by Malaysian garment manufacturers in three key areas - quality systems and tools; quality control and types of inspection; as well as sampling procedures chosen for garment inspection. Besides, the focus of this research was to distinguish the quality approaches adopted by companies that supplied finished garments to both domestic and international markets. Feedback from each company representative has been obtained via online survey, which comprised of five sections and 44 questions on the organizational profile and the quality approaches employed in the garment industry. As a result, the response rate was 31%. The results revealed that almost all companies have established their own mechanism of process control by conducting a series of quality inspections for daily production, either it was formally set up or otherwise. In addition, quality inspection has been the predominant quality control activity in the garment manufacturing, while the level of complexity of these activities was substantially dictated by the customers. Moreover, AQL-based sampling was utilized by companies dealing with exports, whilst almost all the companies that only concentrated on the domestic market were comfortable using their own sampling procedures for garment inspection. Hence, this research has provided insights into the implementation of a number of quality approaches that were perceived as important and useful in the garment manufacturing sector, which is truly labour-intensive.

Keywords: Garment manufacturing, quality approaches, quality control, inspection, acceptance quality limit (AQL), and sampling.

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Authors: F. Rahimi Dehgolan, S. E. Khadem, S. Bab, M. Najafee

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Nowadays, using rotating systems like shafts and disks in industrial machines have been increased constantly. Dynamic stability is one of the most important factors in designing rotating systems. In this study, linear frequencies and stability of a coupled continuous flexible rotor-disk-blades system are studied. The Euler-Bernoulli beam theory is utilized to model the blade and shaft. The equations of motion are extracted using the extended Hamilton principle. The equations of motion have been simplified using the Coleman and complex transformations method. The natural frequencies of the linear part of the system are extracted, and the effects of various system parameters on the natural frequencies and decay rates (stability condition) are clarified. It can be seen that the centrifugal stiffening effect applied to the blades is the most important parameter for stability of the considered rotating system. This result highlights the importance of considering this stiffing effect in blades equation.

Keywords: Rotating shaft, flexible blades, centrifugal stiffening, stability.

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Authors: Julio Molleda, Daniel F. García, Juan C. Granda, Francisco J. Suárez

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One of the main trouble in a steel strip manufacturing line is the breakage of whatever weld carried out between steel coils, that are used to produce the continuous strip to be processed. A weld breakage results in a several hours stop of the manufacturing line. In this process the damages caused by the breakage must be repaired. After the reparation and in order to go on with the production it will be necessary a restarting process of the line. For minimizing this problem, a human operator must inspect visually and manually each weld in order to avoid its breakage during the manufacturing process. The work presented in this paper is based on the Bayesian decision theory and it presents an approach to detect, on real-time, steel strip defective welds. This approach is based on quantifying the tradeoffs between various classification decisions using probability and the costs that accompany such decisions.

Keywords: Classification, Pattern Recognition, ProbabilisticReasoning, Statistical Data Analysis.

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Authors: S. Fore, L. Zuze

Abstract:

Frequent machine breakdowns, low plant availability and increased overtime are a great threat to a manufacturing plant as they increase operating costs of an industry. The main aim of this study was to improve Overall Equipment Effectiveness (OEE) at a manufacturing company through the implementation of innovative maintenance strategies. A case study approach was used. The paper focuses on improving the maintenance in a manufacturing set up using an innovative maintenance regime mix to improve overall equipment effectiveness. Interviews, reviewing documentation and historical records, direct and participatory observation were used as data collection methods during the research. Usually production is based on the total kilowatt of motors produced per day. The target kilowatt at 91% availability is 75 Kilowatts a day. Reduced demand and lack of raw materials particularly imported items are adversely affecting the manufacturing operations. The company had to reset its targets from the usual figure of 250 Kilowatt per day to mere 75 per day due to lower availability of machines as result of breakdowns as well as lack of raw materials. The price reductions and uncertainties as well as general machine breakdowns further lowered production. Some recommendations were given. For instance, employee empowerment in the company will enhance responsibility and authority to improve and totally eliminate the six big losses. If the maintenance department is to realise its proper function in a progressive, innovative industrial society, then its personnel must be continuously trained to meet current needs as well as future requirements. To make the maintenance planning system effective, it is essential to keep track of all the corrective maintenance jobs and preventive maintenance inspections. For large processing plants these cannot be handled manually. It was therefore recommended that the company implement (Computerised Maintenance Management System) CMMS.

Keywords: Maintenance, Manufacturing, Overall Equipment Effectiveness

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Authors: Zeshan Ahmad, Matteo Zoppi, Rezia Molfino

Abstract:

The stiffness of the workpiece is very important to reduce the errors in manufacturing process. The high stiffness of the workpiece can be achieved by optimal positioning of fixture elements in the fixture. The minimization of the sum of the nodal deflection normal to the surface is used as objective function in previous research. The deflection in other direction has been neglected. The 3-2-1 fixturing principle is not valid for metal sheets due to its flexible nature. We propose a new fixture layout optimization method N-3-2-1 for metal sheets that uses the strain energy of the finite elements. This method combines the genetic algorithm and finite element analysis. The objective function in this method is to minimize the sum of all the element strain energy. By using the concept of element strain energy, the deformations in all the directions have been considered. Strain energy and stiffness are inversely proportional to each other. So, lower the value of strain energy, higher will be the stiffness. Two different kinds of case studies are presented. The case studies are solved for both objective functions; element strain energy and nodal deflection. The result are compared to verify the propose method.

Keywords: Fixture layout, optimization, fixturing element, genetic algorithm.

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Authors: Berna Ulutas

Abstract:

Single Minute Exchange of Dies (SMED) mainly focuses on recognition of internal and external activities. It is concerned particularly with transferring internal activities into external ones in as many numbers as possible, by also minimizing the internal ones. The validity of the method and procedures are verified by an application a Styrofoam manufacturing process where setup times are critical for time reduction. Significant time savings have been achieved with minimum investment. Further, the issues related with employer safety and ergonomics principles during die exchange are noted.

Keywords: Die exchange, internal-external set-up, lean manufacturing, single minute die exchange.

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