Search results for: Design for Manufacturing.

Authors: M. Othman, N. Bhuiyan, G. J. Gouw

Abstract:

In today-s global and competitive market, manufacturing companies are working hard towards improving their production system performance. Most companies develop production systems that can help in cost reduction. Manufacturing systems consist of different elements including production methods, machines, processes, control and information systems. Human issues are an important part of manufacturing systems, yet most companies do not pay sufficient attention to them. In this paper, a workforce planning (WP) model is presented. A non-linear programming model is developed in order to minimize the hiring, firing, training and overtime costs. The purpose is to determine the number of workers for each worker type, the number of workers trained, and the number of overtime hours. Moreover, a decision support system (DSS) based on the proposed model is introduced using the Excel-Lingo software interfacing feature. This model will help to improve the interaction between the workers, managers and the technical systems in manufacturing.

Keywords: Decision Support System, Human Factors, Manufacturing System, Workforce Planning.

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Authors: N. Javadian, J. Rezaeian, Y. Maali

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In this paper a multi-objective nonlinear programming model of cellular manufacturing system is presented which minimize the intercell movements and maximize the sum of reliability of cells. We present a genetic approach for finding efficient solutions to the problem of cell formation for products having multiple routings. These methods find the non-dominated solutions and according to decision makers prefer, the best solution will be chosen.

Keywords: Cellular Manufacturing, Genetic Algorithm, Multiobjective, Life-Cycle.

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Authors: Ragi Poyyara, Vivek V., Ashish Khaparde

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The product development process (PDP) in the Technology group plays a very important role in the launch of any product. While a manufacturing process encourages the use of certain measures to reduce health, safety and environmental (HSE) risks on the shop floor, the PDP concentrates on the use of Geometric Dimensioning and Tolerancing (GD&T) to develop a flawless design. Furthermore, PDP distributes and coordinates activities between different departments such as marketing, purchasing, and manufacturing. However, it is seldom realized that PDP makes a significant contribution to developing a product that reduces HSE risks by encouraging the Technology group to use effective GD&T. The GD&T is a precise communication tool that uses a set of symbols, rules, and definitions to mathematically define parts to be manufactured. It is a quality assurance method widely used in the oil and gas sector. Traditionally it is used to ensure the interchangeability of a part without affecting its form, fit, and function. Parts that do not meet these requirements are rejected during quality audits. This paper discusses how the Technology group integrates this quality assurance tool into the PDP and how the tool plays a major role in helping the HSE department in its goal towards eliminating HSE incidents. The PDP involves a thorough risk assessment and establishes a method to address those risks during the design stage. An illustration shows how GD&T helped reduce safety risks by ergonomically improving assembling operations. A brief discussion explains how tolerances provided on a part help prevent finger injury. This tool has equipped Technology to produce fixtures, which are used daily in operations as well as manufacturing. By applying GD&T to create good fits, HSE risks are mitigated for operating personnel. Both customers and service providers benefit from reduced safety risks.

Keywords: HSE, PDP, GD&T, risks.

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Authors: Marco Ryll, Svetan Ratchev

Abstract:

This paper discusses the applicability of the Data Distribution Service (DDS) for the development of automated and modular manufacturing systems which require a flexible and robust communication infrastructure. DDS is an emergent standard for datacentric publish/subscribe middleware systems that provides an infrastructure for platform-independent many-to-many communication. It particularly addresses the needs of real-time systems that require deterministic data transfer, have low memory footprints and high robustness requirements. After an overview of the standard, several aspects of DDS are related to current challenges for the development of modern manufacturing systems with distributed architectures. Finally, an example application is presented based on a modular active fixturing system to illustrate the described aspects.

Keywords: Flexible Manufacturing, Publish/Subscribe, Plug & Produce.

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Authors: Justyna Rybicka, Ashutosh Tiwari, Shane Enticott

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In the age of automation and computation aiding manufacturing, it is clear that manufacturing systems have become more complex than ever before. Although technological advances provide the capability to gain more value with fewer resources, sometimes utilisation of the manufacturing capabilities available to organisations is difficult to achieve. Flexible manufacturing systems (FMS) provide a unique capability to manufacturing organisations where there is a need for product range diversification by providing line efficiency through production flexibility. This is very valuable in trend driven production set-ups or niche volume production requirements. Although FMS provides flexible and efficient facilities, its optimal set-up is key in achieving production performance. As many variables are interlinked due to the flexibility provided by the FMS, analytical calculations are not always sufficient to predict the FMS’ performance. Simulation modelling is capable of capturing the complexity and constraints associated with FMS. This paper demonstrates how discrete event simulation (DES) can address complexity in an FMS to optimise the production line performance. A case study of an automotive FMS is presented. The DES model demonstrates different configuration options depending on prioritising objectives: utilisation and throughput. Additionally, this paper provides insight into understanding the impact of system set-up constraints on the FMS performance and demonstrates the exploration into the optimal production set-up.

Keywords: Automotive, capacity performance, discrete event simulation, flexible manufacturing system.

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Authors: Ahmed E. Hodaib, Samar F. Abdel Fattah

Abstract:

High-speed transportation is a growing concern. To develop high-speed rails and to increase high-speed efficiencies, the idea of Hyperloop was introduced. The challenge is to overcome the difficulties of managing friction and air-resistance which become substantial when vehicles approach high speeds. In this paper, we are presenting the methodologies of the capsule design which got a design concept innovation award at SpaceX competition in January, 2016. MATLAB scripts are written for the levitation and propulsion calculations and iterations. Computational Fluid Dynamics (CFD) is used to simulate the air flow around the capsule considering the effect of the axial-flow air compressor and the levitation cushion on the air flow. The design procedures of a single-sided linear induction motor are analyzed in detail and its geometric and magnetic parameters are determined. A structural design is introduced and Finite Element Method (FEM) is used to analyze the stresses in different parts. The configuration and the arrangement of the components are illustrated. Moreover, comments on manufacturing are made.

Keywords: High-speed transportation, Hyperloop, railways transportation, single-sided linear induction motor.

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Authors: Viraj Tyagi, Ajai Jain, P. K. Jain, Aarushi Jain

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This paper presents a genetic algorithm based loading methodology for a capacity constrained job-shop with the consideration of alternative process plans for each part to be produced. Performance analysis of the proposed methodology is carried out for two case studies by considering two different manufacturing scenarios. Results obtained indicate that the methodology is quite effective in improving the shop load balance, and hence, it can be included in the frameworks of manufacturing planning systems of job-shop oriented industries.

Keywords: Manufacturing planning, loading, genetic algorithm, Job-Shop

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Authors: F.B. Georgise, K. D. Thoben, M. Seifert

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This paper presents a research agenda on the SCOR model adaptation. SCOR model is designated to measure supply chain performance and logistics impact across the boundaries of individual organizations. It is at its growing stage of its life cycle and is enjoying the leverage of becoming the industry standard. The SCOR model has been developed and used widely in developed countries context. This research focuses on the SCOR model adaptation for the manufacturing industry in developing countries. With a necessary understanding of the characteristics, difficulties and problems of the manufacturing industry in developing countries- supply chain; consequently, we will try to designs an adapted model with its building blocks: business process model, performance measures and best practices.

Keywords: developing countries, manufacturing industry, SCOR model adaptation

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Authors: M. K. Holst, P. H. Kirkegaard, L. D. Christoffersen

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Present paper presents a parametric performancebased design model for optimizing hospital design. The design model operates with geometric input parameters defining the functional requirements of the hospital and input parameters in terms of performance objectives defining the design requirements and preferences of the hospital with respect to performances. The design model takes point of departure in the hospital functionalities as a set of defined parameters and rules describing the design requirements and preferences.

Keywords: Architectural Layout Design, Hospital Design, Parametric design, Performance-based models.

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Authors: J. A. López, J. E. Olguín, C. W. Camargo, G. A. Quijano, R. Martínez

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This paper presents an anthropometric study conducted to 300 employees in a maquiladora industry that belongs to the cluster of medical products as part of a research project to pretend simulate workplace conditions under which operators conduct their activities. This project is relevant because traditionally performed a study to design ergonomic workspaces according to anthropometric profile of users, however, this paper demonstrates the importance of making decisions when the infrastructure cannot be adapted for economic whichever put emphasis on user activity.

Keywords: Anthropometry, Biomechanics, Design, Ergonomics, Productivity.

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Authors: S. Z. Sarwar, N. Ehsan , I, Mirza, J. L. Piracha, M. Azeem, A. Ishaque

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The public sector losses are the major cause of stagnant growth of Pakistan. Public sector automotive manufacturing industry is one of the major contributors of these losses. This research has been carried out in order to identify the major barriers of productivity of this industry and suggest measures for improvement. This qualitative and quantitative research consisted of informal interviews, discussions augmented by closed ended questionnaire. Three major manufacturing units were chosen for this research and responses from 103 employees were collected. It was found out in this research that numerous productivity flaws exist in the system which requires immediate attention. Besides highlighting flaws this research also suggests corrective actions and areas for future research to overcome these problems.

Keywords: Automotive manufacturing industry, barriers ofproductivity, Public sector losses.

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Authors: Yanting Cao, Kazumitsu Nawata

Abstract:

The UK has strong economic growth, which attracts other countries to invest there through globalization. This research process will be based on quantitative and qualitative descriptive analysis using interviews. The secondary analysis will involve a case study approach to understand the important aspects of leadership skills. The research outcomes will be identifying the strength and weakness of the leadership skills of UK automobile manufacturing enterprises and suggest the best practices adopted by the respective countries for better results.

Keywords: engineering management, leadership, industrial project management, project managers, automobile manufacturing

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Authors: Yongyoon Suh, Chulhyun Kim, Moon-soo Kim

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As the trend of manufacturing is being dominated depending on services, products and processes are more and more related with sophisticated services. Thus, this research starts with the discussion about integration of the product, process, and service in the innovation process. In particular, this paper sets out some foundations for a theory of service innovation in the field of manufacturing, and proposes the dynamic model of service innovation related to product and process. Two dynamic models of service innovation are suggested to investigate major tendencies and dynamic variations during the innovation cycle: co-innovation and sequential innovation. To structure dynamic models of product, process, and service innovation, the innovation stages in which two models are mainly achieved are identified. The research would encourage manufacturers to formulate strategy and planning for service development with product and process.

Keywords: dynamic model, service innovation, service innovation models, innovation cycle, manufacturing industry.

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Authors: M. S. Abdelwahed, M. A. El-Baz, T. T. El-Midany

Abstract:

this paper aims to provide an approach to predict the performance of the product produced after multi-stages of manufacturing processes, as well as the assembly. Such approach aims to control and subsequently identify the relationship between the process inputs and outputs so that a process engineer can more accurately predict how the process output shall perform based on the system inputs. The approach is guided by a six-sigma methodology to obtain improved performance. In this paper a case study of the manufacture of a hermetic reciprocating compressor is presented. The application of artificial neural networks (ANNs) technique is introduced to improve performance prediction within this manufacturing environment. The results demonstrate that the approach predicts accurately and effectively.

Keywords: Artificial neural networks, Reciprocating compressor manufacturing, Performance prediction, Quality improvement

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Authors: Shih-Wen Hsiao, Rong-Qi Chen, Chien-Yu Lin

Abstract:

The topic of surface flattening plays a vital role in the field of computer aided design and manufacture. Surface flattening enables the production of 2D patterns and it can be used in design and manufacturing for developing a 3D surface to a 2D platform, especially in fashion design. This study describes surface flattening based on minimum energy methods according to the property of different fabrics. Firstly, through the geometric feature of a 3D surface, the less transformed area can be flattened on a 2D platform by geodesic. Then, strain energy that has accumulated in mesh can be stably released by an approximate implicit method and revised error function. In some cases, cutting mesh to further release the energy is a common way to fix the situation and enhance the accuracy of the surface flattening, and this makes the obtained 2D pattern naturally generate significant cracks. When this methodology is applied to a 3D mannequin constructed with feature lines, it enhances the level of computer-aided fashion design. Besides, when different fabrics are applied to fashion design, it is necessary to revise the shape of a 2D pattern according to the properties of the fabric. With this model, the outline of 2D patterns can be revised by distributing the strain energy with different results according to different fabric properties. Finally, this research uses some common design cases to illustrate and verify the feasibility of this methodology.

Keywords: Surface flattening, Strain energy, Minimum energy, approximate implicit method, Fashion design.

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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: S. Aziz, B. Alexander, C. Gengnagel, S. Weinzierl

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This paper explores a generative design, simulation, and optimization workflow for the integration of acoustical diffuser and/or absorber geometry with embedded coupled Helmholtz-resonators for full scale 3D printed building components. Large-scale additive manufacturing in conjunction with algorithmic CAD design tools enables a vast amount of control when creating geometry. This is advantageous regarding the increasing demands of comfort standards for indoor spaces and the use of more resourceful and sustainable construction methods and materials. The presented methodology highlights these new technological advancements and offers a multimodal and integrative design solution with the potential for an immediate application in the AEC-Industry. In principle, the methodology can be applied to a wide range of structural elements that can be manufactured by additive manufacturing processes. The current paper focuses on a case study of an application for a biaxial load-bearing beam grillage made of reinforced concrete, which allows for a variety of applications through the combination of additive prefabricated semi-finished parts and in-situ concrete supplementation. The semi-prefabricated parts or formwork bodies form the basic framework of the supporting structure and at the same time have acoustic absorption and diffusion properties that are precisely acoustically programmed for the space underneath the structure. To this end, a hybrid validation strategy is being explored using a digital and cross-platform simulation environment, verified with physical prototyping. The iterative workflow starts with the generation of a parametric design model for the acoustical geometry using the algorithmic visual scripting editor Grasshopper3D inside the Building Information Modeling (BIM) software Revit. Various geometric attributes (i.e., bottleneck and cavity dimensions) of the resonator are parameterized and fed to a numerical optimization algorithm which can modify the geometry with the goal of increasing absorption at resonance and increasing the bandwidth of the effective absorption range. Using Rhino.Inside and LiveLink for Revit the generative model was imported directly into the Multiphysics simulation environment COMSOL. The geometry was further modified and prepared for simulation in a semi-automated process. The incident and scattered pressure fields were simulated from which the surface normal absorption coefficients were calculated. This reciprocal process was repeated to further optimize the geometric parameters. Subsequently the numerical models were compared to a set of 3D concrete printed physical twin models which were tested in a .25 m x .25 m impedance tube. The empirical results served to improve the starting parameter settings of the initial numerical model. The geometry resulting from the numerical optimization was finally returned to grasshopper for further implementation in an interdisciplinary study.

Keywords: Acoustical design, additive manufacturing, computational design, multimodal optimization.

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Authors: Said Rabah Azzam, Laura Carolina Arias, Shikun Zhou

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A product goes through various processes in a production flow which is also known as assembly line in manufacturing process management. Toyota created a new concept which is known as lean concept in manufacturing industry. Today it is the leading model in manufacturing plants through the globe. The linear walking worker assembly line is a flexible assembly system where each worker travels down the line carrying out each assembly task at each station; and each worker accomplishes the assembly of a unit from start to finish. This paper attempts to combine the flexibility of the walking worker and lean in order to quantify the benefits from applying the shop floor principles of lean management.

Keywords: Toyota Production System, TPS, LeanManufacturing, Walking Worker, Lean Management, Management, Linear Assembly Lines, U-shaped Assembly Lines, Shop FloorManagement

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Authors: Xu LiYun, Briand Florent, Fan GuoLiang

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The loop-layout design problem (LLDP) aims at optimizing the sequence of positioning of the machines around the cyclic production line. Traffic congestion is the usual criteria to minimize in this type of problem, i.e. the number of additional cycles spent by each part in the network until the completion of its required routing sequence of machines. This paper aims at applying several improvements mechanisms such as a positioned-based crossover operator for the Genetic Algorithm (GA) called a Two Points Crossover (TPC) and an offspring selection process. The performance of the improved GA is measured using well-known examples from literature and compared to other evolutionary algorithms. Good results show that GA can still be competitive for this type of problem against more recent evolutionary algorithms.

Keywords: Crossover, genetic algorithm, layout design problem, loop-layout, manufacturing optimization.

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Authors: J.L. Castro, K. Benghazi, M.V. Hurtado, M. Navarro, J.M. Zurita

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Nowadays, quick technological changes force companies to develop innovative products in an increasingly competitive environment. Therefore, how to enhance the time of new product development is very important. This design problem often lacks the exact formula for getting it, and highly depends upon human designers- past experiences. For these reasons, in this work, a Casebased reasoning (CBR) system to assist in new product development is proposed. When a case is recovered from the case base, the system will take into account not only the attribute-s specific value and how important it is. It will also take into account if the attribute has a positive influence over the product development. Hence the manufacturing time will be improved. This information will be introduced as a new concept called “adaptability". An application to this method for hearing instrument new design illustrates the proposed approach.

Keywords: Case based reasoning, Fuzzy logic, New product development, Retrieval stage, Similarity.

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Authors: Sandhya Dixit, Tilak Raj

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Flexible Manufacturing System (FMS) is seen as an option for industries which want to boost productivity as well as respond quickly to an increasingly changing marketplace. FMS produces in mid variety, mid volume range and can meet the changing market demands very quickly. But still the impact of adoption of FMS on the productivity of any industry is not very clear. In this paper an attempt has been made to model the various factors affecting the productivity of FMS installation using Total Interpretive Structural Modelling (TISM) Technique.

Keywords: Flexible manufacturing system, productivity, total interpretive structural modelling.

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Authors: Hermann Kuehnle

Abstract:

Applications of the Hausdorff space and its mappings into tangent spaces are outlined, including their fractal dimensions and self-similarities. The paper details this theory set up and further describes virtualizations and atomization of manufacturing processes. It demonstrates novel concurrency principles that will guide manufacturing processes and resources configurations. Moreover, varying levels of details may be produced by up folding and breaking down of newly introduced generic models. This choice of layered generic models for units and systems aspects along specific aspects allows research work in parallel to other disciplines with the same focus on all levels of detail. More credit and easier access are granted to outside disciplines for enriching manufacturing grounds. Specific mappings and the layers give hints for chances for interdisciplinary outcomes and may highlight more details for interoperability standards, as already worked on the international level. The new rules are described, which require additional properties concerning all involved entities for defining distributed decision cycles, again on the base of self-similarity. All properties are further detailed and assigned to a maturity scale, eventually displaying the smartness maturity of a total shopfloor or a factory. The paper contributes to the intensive ongoing discussion in the field of intelligent distributed manufacturing and promotes solid concepts for implementations of Cyber Physical Systems and the Internet of Things into manufacturing industry, like industry 4.0, as discussed in German-speaking countries.

Keywords: Autonomous unit, Networkability, Smart manufacturing unit, Virtualization.

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Authors: Pankaj Gupta, Amit Kumar Srivastava, Nitesh Pandey

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This article explores the domain of generative design in order to enhance the development of robot designs for innovative and efficient maintenance approaches for tall buildings. This study aims to optimize the design of robotic hands by focusing on minimizing mass and volume while ensuring they can withstand the specified pressure with equal strength. The research procedure is structured and systematic. The purpose of optimization is to enhance the efficiency of the robot and reduce the manufacturing expenses. The project seeks to investigate the application of generative design in order to optimize products. Autodesk Fusion 360 offers the capability to immediately apply the generative design functionality to the solid model. The effort involved creating a solid model of the Smart Glass Cleaning Robot and optimizing one of its components, the Hand, using generative techniques. The article has thoroughly examined the designs, outcomes, and procedure. These loads serve as a benchmark for creating designs that can endure the necessary level of pressure and preserve their structural integrity. The efficacy of the generative design process is contingent upon the selection of materials, as different materials possess distinct physical attributes. The study utilizes five different materials, namely Steel, Stainless Steel, Titanium, Aluminum, and CFRP (Carbon Fiber Reinforced Polymer), in order to investigate a range of design possibilities.

Keywords: Generative design, mass and volume optimization, material strength analysis, generative design, smart glass cleaning robot.

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Authors: Miyoun Won, Youngkyung Choi

Abstract:

In the meantime, there were lots of hardware solutions like products or urban facilities for crime prevention in the public design area. Meanwhile, people have growing interest in public design so by making a village; community design in public design is getting active by the society. The system for crime prevention is actively done by the citizens who created the community. Regarding the social situation, in this project, we saw it as a kind of community design practices and researched about 'how does community design influence Crime prevention?' The purpose of this study is to propose the community design as a way of preventing the crime in the city. First, we found out about the definition, elements and methods of community design by reviewing the theory. And then, this study analyzed the case that was enforced in Seoul and organize the elements and methods of community design. This study can be refer to Public Design based on civil participation and make the community design area contribute to expand the way of solving social problems.

Keywords: Public Design, Sustainable Community Design, Crime Prevention, Participatory Design.

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Authors: Peng Hao Wang, Garam Kim, Ronald Sterkenburg

Abstract:

The applications of composite materials within the aviation industry has been increasing at a rapid pace.  However, the growing applications of composite materials have also led to growing demand for more tooling to support its manufacturing processes. Tooling and tooling maintenance represents a large portion of the composite manufacturing process and cost. Therefore, the industry’s adaptability to new techniques for fabricating high quality tools quickly and inexpensively will play a crucial role in composite material’s growing popularity in the aviation industry. One popular tool fabrication technique currently being developed involves additive manufacturing such as 3D printing. Although additive manufacturing and 3D printing are not entirely new concepts, the technique has been gaining popularity due to its ability to quickly fabricate components, maintain low material waste, and low cost. In this study, a team of Purdue University School of Aviation and Transportation Technology (SATT) faculty and students investigated the effectiveness of a 3D printed composite compression mold. A 3D printed composite compression mold was fabricated by 3D scanning a steel valve cover of an aircraft reciprocating engine. The 3D printed composite compression mold was used to fabricate carbon fiber versions of the aircraft reciprocating engine valve cover. The 3D printed composite compression mold was evaluated for its performance, durability, and dimensional stability while the fabricated carbon fiber valve covers were evaluated for its accuracy and quality. The results and data gathered from this study will determine the effectiveness of the 3D printed composite compression mold in a mass production environment and provide valuable information for future understanding, improvements, and design considerations of 3D printed composite molds.

Keywords: Additive manufacturing, carbon fiber, composite tooling, molds.

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Authors: Atjanakul W, Chutima S., Kamnerdthong T.

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Shipping comb is mounted on Head Stack Assembly (HSA) to prevent collision of the heads, maintain the gap between suspensions and protect HSA tips from unintentional contact damaged in the manufacturing process. Failure analysis of shipping comb in hard disk drive production processes is proposed .Field observations were performed to determine the fatal areas on shipping comb and their failure fraction. Root cause failure analysis (RCFA) is applied to specify the failure causes subjected to various loading conditions. For reliability improvement, failure mode and effects analysis (FMEA) procedure to evaluate the risk priority is performed. Consequently, the more suitable information design criterions were obtained.

Keywords: Shipping comb, Hard disk drive, Root cause failureanalysis, Failure mode and effects analysis

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Authors: T. H. Bitebe, T. M. Lima, F. Charrua-Santos, C. J. Matias Oliveira

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This study aims to present a proposal for an economic integration model for the development of the manufacturing industry in Cabinda, Angola. It seeks to analyze the degree of economic integration of Cabinda and the dynamics of the manufacturing industry. Therefore, in the same way, to gather information to support the decision-making for public financing programs that will aim at the disengagement of the manufacturing industry in Angola and Cabinda in particular. The Cabinda Province is the 18^th of Angola, the enclave is located in a privileged area of the African and arable land.

Keywords: Economic integration, industrial development, Cabinda industry, Angola.

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Authors: Rudi Kurniawan Arief

Abstract:

Manufacturing cost and setup time are the hot topics to improve in Metal Stamping industry because material and components price are always rising up while costumer requires to cut down the component price year by year. The Single Minute Exchange of Die (SMED) is one of many methods to reduce waste in stamping industry. The Japanese Quick Die Change (QDC) dies system is one of SMED systems that could reduce both of setup time and manufacturing cost. However, this system is rarely used in stamping industries. This paper will analyze how deep the QDC dies system could reduce setup time and the manufacturing cost. The research is conducted by direct observation, simulating and comparing of QDC dies system with conventional dies system. In this research, we found that the QDC dies system could save up to 35% of manufacturing cost and reduce 70% of setup times. This simulation proved that the QDC die system is effective for cost reduction but must be applied in several parallel production processes.

Keywords: Press die, metal stamping, quick die change, QDC system, single minute exchange die, manufacturing cost saving, SMED.

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Authors: M. Ramadan, B. Salah

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This paper introduces a framework to digitalize lean manufacturing tools to enhance smart lean-based manufacturing environments or Lean 4.0 manufacturing systems. The paper discusses the integration between lean tools and the powerful features of recent real-time data capturing systems with the help of Information and Communication Technologies (ICT) to develop an intelligent real-time monitoring and controlling system of production operations concerning lean targets. This integration is represented in the Lean 4.0 system called Dynamic Value Stream Mapping (DVSM). Moreover, the paper introduces the practice of Radio Frequency Identification (RFID) and ICT to smartly support lean tools and practices during daily production runs to keep the lean system alive and effective. This work introduces a practical description of how the lean method tools 5S, standardized work, and poka-yoke can be digitalized and smartly monitored and controlled through DVSM. A framework of the three tools has been discussed and put into practice in a German switchgear manufacturer.

Keywords: Lean manufacturing, Industry 4.0, radio frequency identification, value stream mapping.

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

Abstract:

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

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

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