Search results for: Factory Planning Process

Authors: Achim Kampker, Peter Burggräf, Moritz Krunke, Hanno Voet

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As a reaction to current challenges in factory planning, many companies think about introducing factory standards to lower planning times and decrease planning costs. If these factory standards are set-up with a high level of modularity, they are defined as modular factory systems. This paper deals with the main current problems in the application of modular factory systems in practice and presents a solution approach with its basic models. The methodology is based on methods from factory planning but also uses the tools of other disciplines like product development or technology management to deal with the high complexity, which the development of modular factory systems implies. The four basic models that such a methodology has to contain are introduced and pointed out.

Keywords: Factory planning, modular factory systems, factory standards, cost-benefit analysis.

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Authors: Christian Mosch, Reiner Anderl, Antonio Álvaro de Assis Moura, Klaus Schützer

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Due to short product life cycles, increasing variety of products and short cycles of leap innovations manufacturing companies have to increase the flexibility of factory structures. Flexibility of factory structures is based on defined factory planning processes in which product, process and resource data of various partial domains have to be considered. Thus factory planning processes can be characterized as iterative, interdisciplinary and participative processes [1]. To support interdisciplinary and participative character of planning processes, a federative factory data management (FFDM) as a holistic solution will be described. FFDM is already implemented in form of a prototype. The interim results of the development of FFDM will be shown in this paper. The principles are the extracting of product, process and resource data from documents of various partial domains providing as web services on a server. The described data can be requested by the factory planner by using a FFDM-browser.

Keywords: BRAGECRIM, Factory Planning Process, FactoryData Management, Web Services

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Authors: Candy P. Schulze, Michael Brieke, Prof. Peter Nyhuis

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The building of a factory can be a strategic investment owing to its long service life. An evaluation that only focuses, for example, on payments for the building, the technical equipment of the factory, and the personnel for the enterprise is – considering the complexity of the system factory – not sufficient for this long-term view. The success of an investment is secured, among other things, by the attainment of nonmonetary goals, too, like transformability. Such aspects are not considered in traditional investment calculations like the net present value method. This paper closes this gap with the enhanced economic evaluation (EWR) for factory planning. The procedure and the first results of an application in a project are presented.

Keywords: economic efficiency, holistic evaluation, factory planning

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Authors: T. Mersmann, P. Nyhuis

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In the current economic climate, for many businesses it is generally no longer sufficient to pursue exclusively economic interests. Instead, integrating ecological and social goals into the corporate targets is becoming ever more important. However, the holistic integration of these new goals is missing from current factory planning approaches. This article describes the conceptual framework for a planning methodology for sustainable factories. To this end, the description of the key areas for action is followed by a description of the principal components for the systematization of sustainability for factories and their stakeholders. Finally, a conceptual framework is presented which integrates the components formulated into an established factory planning procedure.

Keywords: Factory Planning, Stakeholder, Systematization, Sustainability.

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Authors: Peter Burggräf, Moritz Krunke, Hanno Voet

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Due to shortening product and technology lifecycles, many companies use standardization approaches in product development and factory planning to reduce costs and time to market. Unlike large companies, where modular systems are already widely used, small and medium-sized companies often show a much lower degree of standardization due to lower scale effects and missing capacities for the development of these standards. To overcome these challenges, the development of industry sector specific standards in cooperations or by third parties is an interesting approach. This paper analyzes which branches that are mainly dominated by small or medium-sized companies might be especially interesting for the development of factory standards using the example of the German industry. For this, a key performance indicator based approach was developed that will be presented in detail with its specific results for the German industry structure.

Keywords: Factory planning, factory standards, industry sector specific standardization, production planning.

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Authors: Chun-Wei Lin, Yu-Lin Chen

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As global industry developed rapidly, the energy demand also rises simultaneously. In the production process, there’s a lot of energy consumed in the process. Formally, the energy used in generating the heat in the production process. In the total energy consumption, 40% of the heat was used in process heat, mechanical work, chemical energy and electricity. The remaining 50% were released into the environment. It will cause energy waste and environment pollution. There are many ways for recovering the waste heat in factory. Organic Rankine Cycle (ORC) system can produce electricity and reduce energy costs by recovering the waste of low temperature heat in the factory. In addition, ORC is the technology with the highest power generating efficiency in low-temperature heat recycling. However, most of factories executives are still hesitated because of the high implementation cost of the ORC system, even a lot of heat are wasted. Therefore, this study constructs a nonlinear mathematical model of waste heat recovery equipment configuration to maximize profits. A particle swarm optimization algorithm is developed to generate the optimal facility installation plan for the ORC system.

Keywords: Green facility planning, organic rankine cycle, particle swarm optimization, waste heat recovery.

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Authors: Ömer Faruk Baykoç, Ümit Sami Sakalli

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In this paper, we propose a fuzzy aggregate production planning (APP) model for blending problem in a brass factory which is the problem of computing optimal amounts of raw materials for the total production of several types of brass in a period. The model has deterministic and imprecise parameters which follows triangular possibility distributions. The brass casting APP model can not always be solved by using common approaches used in the literature. Therefore a mathematical model is presented for solving this problem. In the proposed model, the Lai and Hwang-s fuzzy ranking concept is relaxed by using one constraint instead of three constraints. An application of the brass casting APP model in a brass factory shows that the proposed model successfully solves the multi-blend problem in casting process and determines the optimal raw material purchasing policies.

Keywords: Aggregate production planning, Blending, brasscasting, possibilistic programming.

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Authors: Thaniya Kaosol, Sirinthrar Wandee

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In this research, an aerobic composting method is studied to reuse organic waste from rubber factory waste as soil fertilizer and to study the effect of cellulolytic microbial activator (CMA) as the activator in the rubber factory waste composting. The performance of the composting process was monitored as a function of carbon and organic matter decomposition rate, temperature and moisture content. The results indicate that the rubber factory waste is best composted with water hyacinth and sludge than composted alone. In addition, the CMA is more affective when mixed with the rubber factory waste, water hyacinth and sludge since a good fertilizer is achieved. When adding CMA into the rubber factory waste composted alone, the finished product does not achieve a standard of fertilizer, especially the C/N ratio. Finally, the finished products of composting rubber factory waste and water hyacinth and sludge (both CMA and without CMA), can be an environmental friendly alternative to solve the disposal problems of rubber factory waste. Since the C/N ratio, pH, moisture content, temperature, and nutrients of the finished products are acceptable for agriculture use.

Keywords: composting, rubber waste, C/N ratio, sludge, cellulolytic microbial activator

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Authors: L. Richter, J. Lübkemann, P. Nyhuis

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In order to remain competitive in what is a turbulent environment; businesses must be able to react rapidly to change. The past response to volatile market conditions was to introduce an element of flexibility to production. Nowadays, what is often required is a redesign of factory structures in order to cope with the state of constant flux. The Institute of Production Systems and Logistics is currently developing a descriptive and causal model for the redesign of plant structures as part of an ongoing research project. This article presents the first research findings attained in devising this model.

Keywords: Causal model, change driven factory redesign, factory planning, plant structure.

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Authors: A. Kampker, P. Burggräf, Y. Bäumers

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In order to be competitive, companies have to reduce their production costs while meeting increasing quality requirements. Therefore, companies try to plan their assembly processes as detailed as possible. However, increasing product individualization leading to a higher number of variants, smaller batch sizes and shorter product life cycles raise the question to what extent the effort of detailed planning is still justified. An important approach in this field of research is the concept of determining the economic planning depth for assembly process planning based on production specific influencing factors. In this paper first solution hypotheses as well as a first draft of the resulting method will be presented.

Keywords: Assembly process planning, economic planning depth, planning benefit, planning effort.

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Authors: Stephen C. W. Kong

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The use of 3D computer-aided design (CAD) models to support construction project planning has been increasing in the previous year. 3D CAD models reveal more planning ideas by visually showing the construction site environment in different stages of the construction process. Using 3D CAD models together with scheduling software to prepare construction plan can identify errors in process sequence and spatial arrangement, which is vital to the success of a construction project. A number of 4D (3D plus time) CAD tools has been developed and utilized in different construction projects due to the awareness of their importance. Virtual prototyping extends the idea of 4D CAD by integrating more features for simulating real construction process. Virtual prototyping originates from the manufacturing industry where production of products such as cars and airplanes are virtually simulated in computer before they are built in the factory. Virtual prototyping integrates 3D CAD, simulation engine, analysis tools (like structural analysis and collision detection), and knowledgebase to streamline the whole product design and production process. In this paper, we present the application of a virtual prototyping software which has been used in a few construction projects in Hong Kong to support construction project planning. Specifically, the paper presents an implementation of virtual prototyping in a residential building project in Hong Kong. The applicability, difficulties and benefits of construction virtual prototyping are examined based on this project.

Keywords: construction project planning, prefabrication, simulation, virtual prototyping.

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Authors: G. Reinhart, J. Pohl

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Manufacturing companies are facing a broad variety of challenges caused by a dynamic production environment. To succeed in such an environment, it is crucial to minimize the loss of time required to trigger the adaptation process of a company-s production structures. This paper presents an approach for the continuous monitoring of production structures by neurologic principles. It enhances classical monitoring concepts, which are principally focused on reactive strategies, and enables companies to act proactively. Thereby, strategic aspects regarding the harmonization of certain life cycles are integrated into the decision making process for triggering the reconfiguration process of the production structure.

Keywords: Continuous Factory Planning, Production Structure, Production Management.

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Authors: S. Beyou, B. Grondin-Perez, M. Benne, C. Damour, J.-P. Chabriat

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The industrial process of the sugar cane crystallization produces a residual that still contains a lot of soluble sucrose and the objective of the factory is to improve its extraction. Therefore, there are substantial losses justifying the search for the optimization of the process. Crystallization process studied on the industrial site is based on the “three massecuites process". The third step of this process constitutes the final stage of exhaustion of the sucrose dissolved in the mother liquor. During the process of the third step of crystallization (Ccrystallization), the phase that is studied and whose control is to be improved, is the growing phase (crystal growth phase). The study of this process on the industrial site is a problem in its own. A control scheme is proposed to improve the standard PID control law used in the factory. An auto-tuning PID controller based on instantaneous linearization of a neural network is then proposed.

Keywords: Auto-tuning, PID, Instantaneous linearization, Neural network, Non linear process, C-crystallisation.

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Authors: M. P. Amado, C. V. Santos, E. B. Moura, V.G. Silva

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Urban planning, in particular on protected landscape areas, demands an increasing role of public participation within the frame of the efficiency of sustainable planning process. The development of urban planning actions in Protected Landscape areas, as Sintra-Cascais Natural Park, should perform a methodological process that is structured over distinct sequential stages, providing the development of a continuous, interactive, integrated and participative planning. From the start of Malveira da Serra and Janes Plan process, several public participation actions were promoted, in order to involve the local agents, stakeholders and the population in the decision of specific local key issues and define the appropriate priorities within the goals and strategies previously settled. As a result, public participation encouraged an innovative process that guarantees the efficiency of sustainable urban planning and promotes a sustainable new way of living in community.

Keywords: Protected landscape areas, Public participation, Sustainable development, Sustainable planning, Urban planning.

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Authors: D. Pérez, M. M. E. Alemany

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In this work, a framework to model the Supply Chain (SC) Collaborative Planning (CP) process is proposed. The main contributions of this framework concern 1) the presentation of the decision view, the most important one due to the characteristics of the process, jointly within the physical, organisation and information views, and 2) the simultaneous consideration of the spatial and temporal integration among the different supply chain decision centres. This framework provides the basis for a realistic and integrated perspective of the supply chain collaborative planning process and also the analytical modeling of each of its decisional activities.

Keywords: Collaborative Planning, Decision View, Distributed Decision-Making, Framework.

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Authors: Abdulmajeed Bashir Mlitan, Ethan Hack

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Soil samples were collected from and around Alkomos cement factory, Alkomos town, Libya. Soil physiochemical properties were determined. In addition, olive leaves were scanned for their fungal content. This work can conclude that the results obtained for the examined physiochemical characteristics of soil in the area studied prove that cement dust from the Alkomos cement factory in Libya has had a significant impact on the soil. The affected soil properties are pH and total calcium content. These characteristics were found to be higher than those in similar soils from the same area. The increment of soil pH in the same area may be a result of precipitation of cement dust over the years. Different responses were found in each season and each site. For instance, the dominance of fungi of soil and leaves was lowest at 100 m from the factory and the evenness and diversity increased at this site compared to the control area and 250 m from the factory.

Keywords: Pollution, Soil Microbial, Alkomos, Libya.

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Authors: Terezie Bartusková, Jitka Baňařová, Zuzana Kusněřová

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Importance of strategic planning is unquestionable. However, the practical implementation of a strategic plan faces too many obstacles. The aim of the article is explained the importance of strategic planning and to find how companies in Moravian-Silesian Region deal with strategic planning, and to introduce the model, which helps to set strategic goals in financial indicators area. This model should be part of the whole process of strategic planning and can be use to predict the future values of financial indicators of the company with regard to the factor, which influence these indicators.

Keywords: Planning of Potentials, Planning of Strategic Objectives, Portfolio Planning, Significant Factors, Strategic Planning.

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Authors: M. Haddadzade, M. R. Razfar, M. Farahnakian

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Integration of process planning and scheduling functions is necessary to achieve superior overall system performance. This paper proposes a methodology for integration of process planning and scheduling for prismatic component that can be implemented in a company with existing departments. The developed model considers technological constraints whereas available time for machining in shop floor is the limiting factor to produce multiple process plan (MPP). It takes advantage of MPP while guarantied the fulfillment of the due dates via using overtime. This study has been proposed to determinate machining parameters, tools, machine and amount of over time within the minimum cost objective while overtime is considered for this. At last the illustration shows that the system performance is improved by as measured by cost and compatible with due date.

Keywords: Due date, Integration, Multiple process plan, Process planning, Scheduling.

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Authors: Dennis Gossmann, Habil Peter Nyhuis

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Amongst the consistently fluctuating conditions prevailing today, changeability represents a strategic key factor for a manufacturing company to achieve success on the international markets. In order to cope with turbulences and the increasing level of incalculability, not only the flexible design of production systems but in particular the employee as enabler of change provide the focus here. It is important to enable employees from manufacturing companies to participate actively in change events and in change decisions. To this end, the learning factory has been created, which is intended to serve the development of change-promoting competences and the sensitization of employees for the necessity of changes.

Keywords: Changeability, human resources, learning factory.

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Authors: Michael Ajide Oyinloye

Abstract:

Generally the natural environment is made up of air, water and soil. The release of emission of industrial waste into anyone of the components of the environment causes pollution. Industrial pollution significantly threatens the inherent right of people, to the enjoyment of a safe and secure environment. The aim of this paper is to assess the effect of environmental pollution and health risks of residents living near Ewekoro cement factory. The research made use of IKONOS imagery for Geographical Information System (GIS) to buffer and extract buildings that are less than 1km to the factory, within 1km to 5km and above 5km to the factory. Also questionnaire was used to elicit information on the socio-economic factors, effect of environmental pollution on residents and measures adopted to control industrial pollution on the residents. Findings show that most buildings that fall between less than 1km and 1km to 5km to the factory have high health risk in the study area. The study recommended total relocation for the residents of the study area to reduce health risk problems.

Keywords: Environmental pollution, Ewekoro, GIS, Health risk, Satellite imagery.

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Authors: T. Wuttipornpun, U. Wangrakdiskul, W. Songserm

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This paper aims to develop an algorithm of finite capacity material requirement planning (FCMRP) system for a multistage assembly flow shop. The developed FCMRP system has two main stages. The first stage is to allocate operations to the first and second priority work centers and also determine the sequence of the operations on each work center. The second stage is to determine the optimal start time of each operation by using a linear programming model. Real data from a factory is used to analyze and evaluate the effectiveness of the proposed FCMRP system and also to guarantee a practical solution to the user. There are five performance measures, namely, the total tardiness, the number of tardy orders, the total earliness, the number of early orders, and the average flow-time. The proposed FCMRP system offers an adjustable solution which is a compromised solution among the conflicting performance measures. The user can adjust the weight of each performance measure to obtain the desired performance. The result shows that the combination of FCMRP NP3 and EDD outperforms other combinations in term of overall performance index. The calculation time for the proposed FCMRP system is about 10 minutes which is practical for the planners of the factory.

Keywords: Material requirement planning, Finite capacity, Linear programming, Permutation, Application in industry.

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Authors: Fredrik Pettersson

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The paper applies a discourse analytical approach to investigate important concepts influencing the infrastructure planning process in the region of Scania in southern Sweden. Two discourses, one concerning regional development and one concerning sustainability are identified, discussed and contrasted. It is argued that the perceptions of problems and their suggested solutions related to transportation are based on specific ideas, in turn dependent on the importance given to certain concepts, such as regional enlargement, Scania as a transit region, the national environmental quality goals and regional attractiveness. These concepts, their underlying meaning structures and their relevance for the infrastructure planning process are analyzed. The handling of conflicting interests in the planning process, and the possible implications this may have is also discussed. The results indicate that the regional development discourse is dominant and although the solutions to the problems caused by transport are framed in similar ways in the two discourses a harmonization between conflicting goals is proving difficult to achieve.

Keywords: Discourse analysis, Infrastructure planning, Regional development, Sustainability.

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Authors: Balamurugan Baladhandapani, Ganesh Renganathan, V. R. Sanal Kumar

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In this paper a comprehensive review on various factory layouts has been carried out for designing a lucrative process layout for medium scale industries. Industry data base reveals that the end product rejection rate is on the order of 10% amounting large profit loss. In order to avoid these rejection rates and to increase the quality product production an intermediate non-destructive testing facility (INDTF) has been recommended for increasing the overall profit. We observed through detailed case studies that while introducing INDTF to medium scale industries the expensive production process can be avoided to the defective products well before its final shape. Additionally, the defective products identified during the intermediate stage can be effectively utilized for other applications or recycling; thereby the overall wastage of the raw materials can be reduced and profit can be increased. We concluded that the prudent design of a factory layout through critical path method facilitating with INDTF will warrant profitable outcome.

Keywords: Intermediate Non-destructive testing, Medium scale industries, Process layout design.

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Authors: G. Lingam, N. Lingam, K. Raghuwaiya

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In Fiji, notable among the recent spate of educational reforms has been the Ministry of Education’s (MoEs) requirement that all schools undertake a process of school strategic planning. This preliminary study explores perceptions of a sample of Fijian teachers on the way this exercise has been conducted in their schools. The analysis of both quantitative and qualitative data indicates that school leaders’ lack of knowledge and skills in school strategic planning is a major limitation. As an unsurprising consequence, the process(es) schools adopted did not conform to what the literature suggests as best planning practices. School leaders need more training to ensure they are better prepared to carry out this strategic planning effectively, especially in widening the opportunities for all who have a stake in education to contribute to the process. Implications of the findings are likely to be pertinent to other developing contexts within and beyond the Pacific region for the training of school leaders to ensure they are better equipped to orchestrate and benefit from educational reforms thrust upon them.

Keywords: School Strategic Planning, educational reforms.

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Authors: He YuanYan

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In recent years, China has implemented the reform of land and space planning. As an important public policy, land and space planning plays a vital role in the construction and development of cities. Land and space planning throughout the country is in full swing, but there are still many disputes from all walks of life. The content, scope, and specific implementation process of land and space planning are also ambiguous, leading to the integration of multiple regulation problems such as unclear authority, unclear responsibilities, and poor planning results during the implementation of land and space planning. Therefore, it is necessary to sort out the development and evolution of domestic and foreign land space planning, clarify the problems and cruxes from the current situation of China's land space planning, and sort out the obstacles and countermeasures to the implementation of this policy, so as to deepen the understanding of the connotation of land space planning. It is of great practical significance for all planners to correctly understand and clarify the specific contents and methods of land space planning and to smoothly promote the implementation of land space planning at all levels.

Keywords: Territorial spatial planning, public policy, land space, overall planning.

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Authors: Shiva Abdoli, Daniel T. Semere

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Several researches have been conducted to study consumption of energy in cutting process. Most of these researches are focusing to measure the consumption and propose consumption reduction methods. In this work, the relation between the cutting parameters and the consumption is investigated in order to establish a generalized energy consumption model that can be used for process and production planning in real production lines. Using the generalized model, the process planning will be carried out by taking into account the energy as a function of the selected process parameters. Similarly, the generalized model can be used in production planning to select the right operational parameters like batch sizes, routing, buffer size, etc. in a production line. The description and derivation of the model as well as a case study are given in this paper to illustrate the applicability and validity of the model.

Keywords: Process parameters, cutting process, energy efficiency, Material Removal Rate (MRR).

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Authors: Visuwan D., Phruksaphanrat B

Abstract:

In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout. In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout. 

Keywords: Layout, Electronic Manufacturing Service Plant (EMS), Computer Simulation, Cellular Manufacturing System (CMS).

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Authors: Halil Ibrahim Demir, Alper Goksu, Onur Canpolat, Caner Erden, Melek Nur

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Traditionally process planning, scheduling and due date assignment are performed sequentially and separately. High interrelation between these functions makes integration very useful. Although there are numerous works on integrated process planning and scheduling and many works on scheduling with due date assignment, there are only a few works on the integration of these three functions. Here we tested the different integration levels of these three functions and found a fully integrated version as the best. We applied genetic search and random search and genetic search was found better compared to the random search. We penalized all earliness, tardiness and due date related costs. Since all these three terms are all undesired, it is better to penalize all of them.

Keywords: Process planning, scheduling, due-date assignment, genetic algorithm, random search.

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Authors: Chaimongkol Limpianchob

Abstract:

This work addresses the problem of production planning that arises in the production of aromatic coconuts from Samudsakhorn province in Thailand. The planning involves the forwarding of aromatic coconuts from the harvest areas to the factory, which is classified into two groups; self-owned areas and contracted areas, the decisions of aromatic coconuts flow in the plant, and addressing a question of which warehouse will be in use. The problem is formulated as a mixed-integer linear programming model within supply chain management framework. The objective function seeks to minimize the total cost including the harvesting, labor and inventory costs. Constraints on the system include the production activities in the company and demand requirements. Numerical results are presented to demonstrate the feasibility of coconuts supply chain model compared with base case.

Keywords: Aromatic coconut, supply chain management, production planning, mixed-integer linear programming.

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Authors: Phayong Thepaksorn

Abstract:

The objective of this study was to assess whether living in proximity to a roofing fiber cement factory in southern Thailand was associated with physical, mental, social, and spiritual health domains measured in a self-reported health risk assessment (HRA) questionnaire. A cross-sectional study was conducted among community members divided into two groups: near population (living within 0-2km of factory) and far population (living within 2-5km of factory) (N=198). A greater proportion of those living far from the factory (65.34%) reported physical health problems than the near group (51.04%) (p =0.032). This study has demonstrated that the near population group had higher proportion of participants with positive ratings on mental assessment (30.34%) and social health impacts (28.42%) than far population group (10.59% and 16.67%, respectively) (p <0.001). The near population group (29.79%) had similar proportion of participants with positive ratings in spiritual health impacts compared with far population group (27.08%). Among females, but not males, this study demonstrated that a higher proportion of the near population had a positive summative score for the self-HRA, which included all four health domain, compared to the far population (p<0.001 for females; p = 0.154 for males). In conclusion, this self-HRA of physical, mental, social, and spiritual health domains reflected the risk perceptions of populations living in the vicinity of the roofing fiber cement factory. This type of tool can bring attention to population concerns and complaints in the factory’s surrounding community. Our findings may contribute to future development of self-HRA for HIA development procedure in Thailand.

Keywords: Cement dust, health impact assessment, risk assessment, walk-though survey.

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