Search results for: Manufacturing Lead Time

Authors: Ahmad Majdi Bin Abdul-Rani, Mesfin Gizaw, Yusri Yusof

Abstract:

Researches related to standard product model and development of neutral manufacturing interfaces for numerical control machines becomes a significant topic since the last 25 years. In this paper, a detail description of STEP implementation on turnmill manufacturing has been discussed. It shows requirements of information contents from ISO14649 data model. It covers to describe the design of STEP-NC framework applicable to turn-mill manufacturing. In the framework, EXPRESS-G and UML modeling tools are used to depict the information contents of the system and established the bases of information model requirement. A product and manufacturing data model applicable for STEP compliant manufacturing. The next generation turn-mill operations requirements have been represented by a UML diagram. An object oriented classes of ISO1449 has been developed on Visual Basic dot NET platform for binding the static information model represented by the UML diagram. An architect of the proposed system implementation has been given on the bases of the design and manufacturing module of STEP-NC interface established. Finally, a part 21 file process plan generated for an illustration of turn-mill components.

Keywords: CAPP, ISO14649, Product modeling, STEP-NC

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Authors: Yousef S. Al-Othman

Abstract:

The growth and expansion of the industrial facilities comes proportional to the market increasing demand of products and services. Furthermore, raw material producers such as oil companies usually undergo massive revamping projects to maintain a synchronized supply. These revamping projects are usually delivered through challenging construction projects held and associated with daily site risks related to the construction process. Henceforth, a case study related to these risks and corresponding on-spot corrective measurements has been made on a certain number of construction project contractors at Kuwait Oil Company (KOC) to derive the benefits and overall effectiveness of the on-spot corrective measurements during the construction phase of a project, and how would the same help in avoiding major incidents, ensuring a smooth, cost effective and on time delivery of the project. Findings of this case study shall have an added value to the overall risk management process by minimizing the daily site risks that may affect the project lead time, resulting in an undisturbed on-site construction process.

Keywords: Oil and gas, risk management, construction projects, project lead time.

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Authors: Kailash, Rajeev Kumar Saha, Sanjeev Goyal

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Each and every manufacturing industry has a goal that describes its purpose and destination. The goal of any industry may be achieved by team work and managerial skills of all departments. However, achieving goals and objectives is not enough to improve the internal supply chain management performance of manufacturing industries therefore proper identification of performance indicators for benchmarking of internal supply chain management is essential for the growth of manufacturing industry. The identification of benchmarking performance indicators and their impact on internal supply chain management performance is vital for productivity and performance improvement. This study identifies the benchmarking performance indicators to improve internal supply chain performance of Indian manufacturing industries through literature review.

Keywords: Benchmarking, Internal supply chain management, performance indicators, scenario of Indian manufacturing industries.

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Authors: Manuel Seidel, Rainer Seidel, Des Tedford, Richard Cross, Logan Wait

Abstract:

Small and Medium Sized Enterprises (SMEs) play an important role in many economies. In New Zealand, for example, 97% of all manufacturing companies employ less than 100 staff, and generate the predominant part of this industry sector-s economic output. Manufacturing SMEs as a group also have a significant impact on the environment. This situation is similar in many developed economies, including the European Union. Sustainable economic development therefore needs to strongly consider the role of manufacturing SMEs, who generally find it challenging to move towards more environmentally friendly business practices. This paper presents a systems thinking approach to modelling and understanding the factors which have an influence on the successful uptake of environmental practices in small and medium sized manufacturing companies. It presents a number of causal loop diagrams which have been developed based on primary action research, and a thorough understanding of the literature in this area. The systems thinking model provides the basis for further development of a strategic framework for the successful uptake of environmental innovation in manufacturing SMEs.

Keywords: Environmentally benign manufacturing, SMEs, Systems modeling.

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Authors: Khalid Safaa Hashim Al Khalidy, Ali Jalil Abdul Kareem Chabuk, Majid Mohammed Ali Kadhim

Abstract:

This research aims to study the lead pollution in the air of Babylon governorate that resulted generally from vehicles exhausts in addition to industrial and human activities.Vehicles number in Babylon governorate increased significantly after year 2003 that resulted with increase in lead emissions into the air.Measurement of lead emissions was done in seven stations distributed randomly in Babylon governorate. These stations where located in Industrial (Al-Sena'ay) Quarter, 60 street (near to Babylon sewer directorate), 40 Street (near to the first intersection), Al-Hashmia city, Al-Mahaweel city, , Al- Musayab city in addition to another station in Sayd Idris village belong to Abugharaq district (Agricultural station for comparison). The measured concentrations in these stations were compared with the standard limits of Environmental Protection Agency EPA (2 μg /m3). The results of this study showed that the average of lead concentrations ,in Babylon governorate during year 2010, was (3.13 μg/m3) which was greater than standard limits (2 μg/m3). The maximum concentration of lead was (6.41 μg / m3) recorded in the Industrial (Al-Sena'ay) Quarter during April month, while the minimum concentrations was (0.36 μg / m3) recorded in the agricultural station (Abugharaq) during December month.

Keywords: Lead, pollution, lead concentration

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Authors: Mahmoud A. Rabah

Abstract:

The present study shows a method to recover lead metal from wastewater of wet scrubber in secondary lead smelter. The wastewater is loaded with 42,000 ppm of insoluble lead compounds (TSP) submicron in diameter. The technical background benefits the use of cationic polyfloc solution to flocculate these colloidal solids before press filtration. The polymer solution is injected in the wastewater stream in a countercurrent flow design. The study demonstrates the effect of polymer dose, temperature, pH, flow velocity of the wastewater and different filtration media on the filtration extent. Results indicated that filtration rate (¦_r), quality of purified water, purifying efficiency (¦_e) and floc diameter decrease regularly with increase in mass flow rate and velocity up to turbulence of 0.5 m.sec^-1. Laminar flow is in favor of flocculation. Polyfloc concentration of 0.75 – 1.25 g/m³ wastewater is convenient. Increasing temperature of the wastewater and pneumatic pressure of filtration enhances ¦_r. High pH value deforms floc formation and assists degradation of the filtration fabric. The overall efficiency of the method amounts to 93.2 %. Lead metal was recovered from the filtrate cake using carbon as a reducing agent at 900°C.

Keywords: Wastewater, wet scrubbers, filtration, secondary lead.

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Authors: J. A. Mayouf, Q. A. Najim, H. S. Al-Bayati

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The concentrations of cadmium and lead in sewage sludge samples were determined by Atomic Absorption Spectrometric Method. Samples of sewage sludge were obtained from three sewage treatment plants localised in Middle Region of Libya (Misrata, Msallata and Tarhünah cities). The results shows that, the mean levels of Cadmium for all regions are ranges from 81 to 123.4 ppm and these values are higher than the limitations for the international standard which are not registered more than 50 ppm (dry weight) in USA, Egypt and the EU countries. While, the lead concentrations are ranged from 8.0 to 189.2 ppm and all values are within the standard limits which graduated between (275–613) ppm.

Keywords: Cadmium, Lead, Sewage, Spectrometry.

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Authors: L. Rozumová, J. Seidlerová

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The aim of this paper was to study the sorption properties of a blast furnace sludge used as the sorbent. The sorbent was utilized for reduction of content of lead and zinc ions. Sorbent utilized in this work was obtained from metallurgical industry from process of wet gas treatment in iron production. The blast furnace sludge was characterized by X-Ray diffraction, scanning electron microscopy, and XRFS spectroscopy. Sorption experiments were conducted in batch mode. The sorption of metal ions in the sludge was determined by correlation of adsorption isotherm models. The adsorption of lead and zinc ions was best fitted with Langmuir adsorption isotherms. The adsorption capacity of lead and zinc ions was 53.8 mg.g^-1 and 10.7 mg.g^-1, respectively. The results indicated that blast furnace sludge could be effectively used as secondary material and could be also employed as a low-cost alternative for the removal of heavy metals ions from wastewater.

Keywords: Blast furnace sludge, lead, zinc, sorption.

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Authors: S. Homrossukon, W. Parinyasart

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This is an applied research to propose the method for price quotation for a contract electronics manufacturer. It has had a precise price quoting method but such method could not quickly provide a result as the customer required. This reduces the ability of company to compete in this kind of business. In this case, the cause of long time quotation process was analyzed. A lot of product features have been demanded by customer. By checking routine processes, it was found that high fraction of quoting time was used for production time estimating which has effected to the manufacturing or production cost. Then the historical data of products including types, number of components, assembling method, and their assembling time were used to analyze the key components affecting to production time. The price quoting model then was proposed. The implementation of proposed model was able to remarkably reduce quoting time with an acceptable required precision.

Keywords: Price quoting, Contract manufacturer, Stepwise technique, Best subset technique.

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Authors: Wayan F. Mahmudy, Romeo M. Marian, Lee H. S. Luong

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This paper presents modeling and optimization of two NP-hard problems in flexible manufacturing system (FMS), part type selection problem and loading problem. Due to the complexity and extent of the problems, the paper was split into two parts. The first part of the papers has discussed the modeling of the problems and showed how the real coded genetic algorithms (RCGA) can be applied to solve the problems. This second part discusses the effectiveness of the RCGA which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.

Keywords: Flexible manufacturing system, production planning, part type selection problem, loading problem, real-coded genetic algorithm

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Authors: Wayan F. Mahmudy, Romeo M. Marian, Lee H. S. Luong

Abstract:

 This paper deals with modeling and optimization of two NP-hard problems in production planning of flexible manufacturing system (FMS), part type selection problem and loading problem. The part type selection problem and the loading problem are strongly related and heavily influence the system’s efficiency and productivity. These problems have been modeled and solved simultaneously by using real coded genetic algorithms (RCGA) which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.

Keywords: Flexible manufacturing system, production planning, part type selection problem, loading problem, real-coded genetic algorithm.

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Authors: Dorota Stadnicka, Katarzyna Antosz

Abstract:

The idea of Lean Manufacturing has been known for 20 years. In Polish enterprises its first implementation took place in the automotive industry in the 90s. Many companies, in order to reduce costs, use lower quality materials or overload employees with work and do not notice other possibilities for improving the company’s effectiveness. Enterprises are afraid of the unknown. And that is the problem in many cases with the Lean Manufacturing conception. This article presents the study results conducted in enterprises, the aim of which was to identify waste awareness and the need of lean manufacturing implementation. The authors also wanted to gain information on the most commonly used tools and the way of implementation and the methods of the effects assessment of using the mentioned conception. The study was conducted in large enterprises located on a limited area.

Keywords: Large enterprises, lean manufacturing, tools, wastes elimination.

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Authors: Bahaa Eltahawy, Mikko Ylihärsilä, Reino Virrankoski, Esko Petäjä

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Sheet metal processing is automated, but the step from product models to the production machine control still requires human intervention. This may cause time consuming bottlenecks in the production process and increase the risk of human errors. In this paper we present a system, which automatically recognizes features from the CAD-model of the sheet metal product. By using these features, the system produces a complete model of the particular sheet metal product. Then the model is used as an input for the sheet metal processing machine. Currently the system is implemented, capable to recognize more than 11 of the most common sheet metal structural features, and the procedure is fully automated. This provides remarkable savings in the production time, and protects against the human errors. This paper presents the developed system architecture, applied algorithms and system software implementation and testing.

Keywords: Feature recognition, automation, sheet metal manufacturing, CAM, CAD.

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Authors: J. C. T. Benavente, J. C. E. Ferreira

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The rapid development of manufacturing and information systems has caused significant changes in manufacturing environments in recent decades. Mass production has given way to flexible manufacturing systems, in which an important characteristic is customized or "on demand" production. In this scenario, the seamless and without gaps information flow becomes a key factor for success of enterprises. In this paper we present a framework to support the mapping of features into machining workingsteps compliant with the ISO 14649 standard (known as STEP-NC). The system determines how the features can be made with the available manufacturing resources. Examples of the mapping method are presented for features such as a pocket with a general surface.

Keywords: Features, ISO 14649 standard, STEP-NC, mapping, machining workingsteps.

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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: Vivek V, Hafeez Syed, Darren W Terrell, Harit Naik, Halliburton

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Applying a rigorous process to optimize the elements of a supply-chain network resulted in reduction of the waiting time for a service provider and customer. Different sources of downtime of hydraulic pressure controller/calibrator (HPC) were causing interruptions in the operations. The process examined all the issues to drive greater efficiencies. The issues included inherent design issues with HPC pump, contamination of the HPC with impurities, and the lead time required for annual calibration in the USA. HPC is used for mandatory testing/verification of formation tester/pressure measurement/logging-while drilling tools by oilfield service providers, including Halliburton. After market study andanalysis, it was concluded that the current HPC model is best suited in the oilfield industry. To use theexisting HPC model effectively, design andcontamination issues were addressed through design and process improvements. An optimum network is proposed after comparing different supply-chain models for calibration lead-time reduction.

Keywords: Hydraulic Pressure Controller/Calibrator, M/LWD, Pressure, FTWD

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Authors: V. Barot, S. McLeod, R. Harrison, A. A. West

Abstract:

Manufacturing Industries face a crucial change as products and processes are required to, easily and efficiently, be reconfigurable and reusable. In order to stay competitive and flexible, situations also demand distribution of enterprises globally, which requires implementation of efficient communication strategies. A prototype system called the “Broadcaster" has been developed with an assumption that the control environment description has been engineered using the Component-based system paradigm. This prototype distributes information to a number of globally distributed partners via an adoption of the circular-based data processing mechanism. The work highlighted in this paper includes the implementation of this mechanism in the domain of the manufacturing industry. The proposed solution enables real-time remote propagation of machine information to a number of distributed supply chain client resources such as a HMI, VRML-based 3D views and remote client instances regardless of their distribution nature and/ or their mechanisms. This approach is presented together with a set of evaluation results. Authors- main concentration surrounds the reliability and the performance metric of the adopted approach. Performance evaluation is carried out in terms of the response times taken to process the data in this domain and compared with an alternative data processing implementation such as the linear queue mechanism. Based on the evaluation results obtained, authors justify the benefits achieved from this proposed implementation and highlight any further research work that is to be carried out.

Keywords: Broadcaster, circular buffer, Component-based, distributed manufacturing, remote data propagation.

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Authors: Ingy A. El-Khouly, Khaled S. El-Kilany, Aziz E. El-Sayed

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The process of wafer fabrication is arguably the most technologically complex and capital intensive stage in semiconductor manufacturing. This large-scale discrete-event process is highly reentrant, and involves hundreds of machines, restrictions, and processing steps. Therefore, production control of wafer fabrication facilities (fab), specifically scheduling, is one of the most challenging problems that this industry faces. Dispatching rules have been extensively applied to the scheduling problems in semiconductor manufacturing. Moreover, lot release policies are commonly used in this manufacturing setting to further improve the performance of such systems and reduce its inherent variability. In this work, simulation is used in the scheduling of re-entrant flow shop manufacturing systems with an application in semiconductor wafer fabrication; where, a simulation model has been developed for the Intel Five-Machine Six Step Mini-Fab using the ExtendTM simulation environment. The Mini-Fab has been selected as it captures the challenges involved in scheduling the highly re-entrant semiconductor manufacturing lines. A number of scenarios have been developed and have been used to evaluate the effect of different dispatching rules and lot release policies on the selected performance measures. Results of simulation showed that the performance of the Mini-Fab can be drastically improved using a combination of dispatching rules and lot release policy.

Keywords: Dispatching rules, lot release policy, re-entrant flowshop, semiconductor manufacturing.

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Authors: Sachin Man Bajimaya, SangChul Park, Gi-Nam Wang

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The objective of this paper is to estimate realistic principal extrusion process parameters by means of artificial neural network. Conventionally, finite element analysis is used to derive process parameters. However, the finite element analysis of the extrusion model does not consider the manufacturing process constraints in its modeling. Therefore, the process parameters obtained through such an analysis remains highly theoretical. Alternatively, process development in industrial extrusion is to a great extent based on trial and error and often involves full-size experiments, which are both expensive and time-consuming. The artificial neural network-based estimation of the extrusion process parameters prior to plant execution helps to make the actual extrusion operation more efficient because more realistic parameters may be obtained. And so, it bridges the gap between simulation and real manufacturing execution system. In this work, a suitable neural network is designed which is trained using an appropriate learning algorithm. The network so trained is used to predict the manufacturing process parameters.

Keywords: Artificial Neural Network (ANN), Indirect Extrusion, Finite Element Analysis, MES.

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Authors: Chongtham Jiten, K. Chandramani Singh, Radhapiyari Laishram

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Nanocrystalline powders of the lead-free piezoelectric material, tantalum-substituted potassium sodium niobate (K0.5Na0.5)(Nb0.9Ta0.1)O3 (KNNT), were produced using a Retsch PM100 planetary ball mill by setting the milling time to 15h, 20h, 25h, 30h, 35h and 40h, at a fixed speed of 250rpm. The average particle size of the milled powders was found to decrease from 12nm to 3nm as the milling time increases from 15h to 25h, which is in agreement with the existing theoretical model. An anomalous increase to 98nm and then a drop to 3nm in the particle size were observed as the milling time further increases to 30h and 40h respectively. Various sizes of these starting KNNT powders were used to investigate the effect of milling time on the microstructure, dielectric properties, phase transitions and piezoelectric properties of the resulting KNNT ceramics. The particle size of starting KNNT was somewhat proportional to the grain size. As the milling time increases from 15h to 25h, the resulting ceramics exhibit enhancement in the values of relative density from 94.8% to 95.8%, room temperature dielectric constant (εRT) from 878 to 1213, and piezoelectric charge coefficient (d33) from 108pC/N to 128pC/N. For this range of ceramic samples, grain size refinement suppresses the maximum dielectric constant (εmax), shifts the Curie temperature (Tc) to a lower temperature and the orthorhombic-tetragonal phase transition (Tot) to a higher temperature. Further increase of milling time from 25h to 40h produces a gradual degradation in the values of relative density, εRT, and d33 of the resulting ceramics.

Keywords: Ceramics, Dielectric, High-energy milling, Perovskite.

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

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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: Sahar Sohrabi

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The emergence of Cloud data centers has revolutionized the IT industry. Private Clouds in specific provide Cloud services for certain group of customers/businesses. In a real-time private Cloud each task that is given to the system has a deadline that desirably should not be violated. Scheduling tasks in a real-time private CLoud determine the way available resources in the system are shared among incoming tasks. The aim of the scheduling policy is to optimize the system outcome which for a real-time private Cloud can include: energy consumption, deadline violation, execution time and the number of host switches. Different scheduling policies can be used for scheduling. Each lead to a sub-optimal outcome in a certain settings of the system. A Bayesian Scheduling strategy is proposed for scheduling to further improve the system outcome. The Bayesian strategy showed to outperform all selected policies. It also has the flexibility in dealing with complex pattern of incoming task and has the ability to adapt.

Keywords: Bayesian, cloud computing, real-time private cloud, scheduling.

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Authors: Ali Nadi, Ali Edrissi

Abstract:

Relief demand and transportation links availability is the essential information that is needed for every natural disaster operation. This information is not in hand once a disaster strikes. Relief demand and network condition has been evaluated based on prediction method in related works. Nevertheless, prediction seems to be over or under estimated due to uncertainties and may lead to a failure operation. Therefore, in this paper a stochastic programming model is proposed to evaluate real-time relief demand and network condition at the onset of a natural disaster. To address the time sensitivity of the emergency response, the proposed model uses reinforcement learning for optimization of the total relief assessment time. The proposed model is tested on a real size network problem. The simulation results indicate that the proposed model performs well in the case of collecting real-time information.

Keywords: Disaster management, real-time demand, reinforcement learning, relief demand.

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Authors: Mahmoud A. El-Banna

Abstract:

The need to increase the efficiency of health care systems is becoming an obligation, and one of area of improvement is the discharge process. The objective of this work is to minimize the patients discharge time (for insured patients) to be less than 50 minutes by using six sigma approach, this improvement will also: lead to an increase in customer satisfaction, increase the number of admissions and turnover on the rooms, increase hospital profitability.Three different departments were considered in this study: Female, Male, and Paediatrics. Six Sigma approach coupled with simulation has been applied to reduce the patients discharge time for pediatrics, female, and male departments at hospital. Upon applying these recommendations at hospital: 60%, 80%, and 22% of insured female, male, and pediatrics patients respectively will have discharge time less than the upper specification time i.e. 50 min.

Keywords: Discharge Time, Healthcare, Hospitals, Patients, Process Improvement, Six Sigma, Simulation

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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: Roscoe McLean, Jared Padayachee, Glen Bright

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There is currently a gap in the technology covering the rapid establishment of control after a reconfiguration in a Reconfigurable Manufacturing System. This gap involves the detection of the factory floor state and the communication link between the factory floor and the high-level software. In this paper, a thin, hardware-supported Middleware Management System (MMS) is proposed and its design and implementation are discussed. The research found that a cost-effective localization technique can be combined with intelligent software to speed up the ramp-up of a reconfigured system. The MMS makes the process more intelligent, more efficient and less time-consuming, thus supporting the industrial implementation of the RMS paradigm.

Keywords: Intelligent systems, middleware, reconfigurable manufacturing.

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Authors: S. G. Ponnambalam, Low Seng Kiat

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In this paper, a particle swarm optimization (PSO) algorithm is proposed to solve machine loading problem in flexible manufacturing system (FMS), with bicriterion objectives of minimizing system unbalance and maximizing system throughput in the occurrence of technological constraints such as available machining time and tool slots. A mathematical model is used to select machines, assign operations and the required tools. The performance of the PSO is tested by using 10 sample dataset and the results are compared with the heuristics reported in the literature. The results support that the proposed PSO is comparable with the algorithms reported in the literature.

Keywords: Machine loading problem, FMS, Particle Swarm Optimization.

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Authors: A. Razavykia, A. Esmaeilzadeh, S. Iranmanesh

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Many orthopedic implants like proximal humerus cases require lower surface roughness and almost immediate/short lead time surgery. Thus, rapid response from the manufacturer is very crucial. Tool path strategy of milling process has a direct influence on the surface roughness and lead time of medical implant. High-speed milling as promised process would improve the machined surface quality, but conventional or super-abrasive grinding still required which imposes some drawbacks such as additional costs and time. Currently, many CAD/CAM software offers some different tool path strategies to milling free form surfaces. Nevertheless, the users must identify how to choose the strategies according to cutting tool geometry, geometry complexity, and their effects on the machined surface. This study investigates the effect of different tool path strategies for milling a proximal humerus head during finishing operation on stainless steel 316L. Experiments have been performed using MAHO MH700 S vertical milling machine and four machining strategies, namely, spiral outward, spiral inward, and radial as well as zig-zag. In all cases, the obtained surfaces were analyzed in terms of roughness and dimension accuracy compared with those obtained by simulation. The findings provide evidence that surface roughness, dimensional accuracy, and machining time have been affected by the considered tool path strategy.

Keywords: CAD/CAM software, milling, orthopedic implants, tool path strategy.

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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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