Search results for: Production Ramp Up.

Authors: Sebastian Tschöpe, Konja Knüppel, Peter Nyhuis

Abstract:

In times when product life cycles are decreasing, while market demands are increasing, manufacturing enterprises are confronted with the challenge of more frequent and more complex ramp-ups. Thus it becomes obvious that ramp-up management is going to be a topic enterprises have to focus on in the future. Since each ramp-up is unique concerning the product, the process, the technology, the circumstances and the coaction of these four factors, the knowledge of the ramp-up situation and the current ramp-up capability of the enterprise are fundamental requirements for the subsequent improvement of the ramp-up capability of the production system.

In this article a methodology is going to be presented which can be used to define typical production ramp-up situations, to identify the current ramp-up capability of a production system and to improve it with respect to a specific situation. Additionally there will be a description of the functionality of a software-tool developed based on this methodology.

Keywords: Assessment methodology, ramp-up, ramp-up capability, software-tool.

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Authors: M. Goerke, J. Gehrmann

Abstract:

Caused by shorter product life cycles and higher product variety the importance of production ramp ups is increasing. Even though companies are aware of that fact, up to 40% of the ramp up projects still miss technical and economical requirements. The success of a ramp up depends on the planning of human factors, organizational aspects and technological solutions. Since only partly considered in scientific literature, this paper lays its focus on the human factor during production ramp up. There are only incoherent methods which address the problems in this area. A systematic and holistic method to improve the capabilities of the employees during ramp up is missing. The Harada Method is a relatively young approach for developing highly-skilled workers. It consists of different worksheets which help employees to set guidelines and reach overall objectives. This approach is going to be transferred into a tool for ramp up management.

Keywords: Employee Development, Harada, Production Ramp Up.

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

Abstract:

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

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

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Authors: Himanshu Shekhar Maharana, S. K .Dash

Abstract:

Economic Load Dispatch (ELD) proves to be a vital optimization process in electric power system for allocating generation amongst various units to compute the cost of generation, the cost of emission involving global warming gases like sulphur dioxide, nitrous oxide and carbon monoxide etc. In this dissertation, we emphasize ramp rate constriction factor based particle swarm optimization (RRCPSO) for analyzing various performance objectives, namely cost of generation, cost of emission, and a dual objective function involving both these objectives through the experimental simulated results. A 6-unit 30 bus IEEE test case system has been utilized for simulating the results involving improved weight factor advanced ramp rate limit constraints for optimizing total cost of generation and emission. This method increases the tendency of particles to venture into the solution space to ameliorate their convergence rates. Earlier works through dispersed PSO (DPSO) and constriction factor based PSO (CPSO) give rise to comparatively higher computational time and less good optimal solution at par with current dissertation. This paper deals with ramp rate and constriction factor based well defined ramp rate PSO to compute various objectives namely cost, emission and total objective etc. and compares the result with DPSO and weight improved PSO (WIPSO) techniques illustrating lesser computational time and better optimal solution. 

Keywords: Economic load dispatch, constriction factor based particle swarm optimization, dispersed particle swarm optimization, weight improved particle swarm optimization, ramp rate and constriction factor based particle swarm optimization.

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Authors: Susanta Kumar Gachhayat, S. K. Dash

Abstract:

Multi objective non-convex economic dispatch problems of a thermal power plant are of grave concern for deciding the cost of generation and reduction of emission level for diminishing the global warming level for improving green-house effect. This paper deals with ramp rate constraints for achieving better inequality constraints so as to incorporate valve point loading for cost of generation in thermal power plant through ramp rate biogeography based optimization involving mutation and migration. Through 50 out of 100 trials, the cost function and emission objective function were found to have outperformed other classical methods such as lambda iteration method, quadratic programming method and many heuristic methods like particle swarm optimization method, weight improved particle swarm optimization method, constriction factor based particle swarm optimization method, moderate random particle swarm optimization method etc. Ramp rate biogeography based optimization applications prove quite advantageous in solving non convex multi objective economic dispatch problems subjected to nonlinear loads that pollute the source giving rise to third harmonic distortions and other such disturbances.

Keywords: Economic load dispatch, Biogeography based optimization, Ramp rate biogeography based optimization, Valve Point loading, Moderate random particle swarm optimization method, Weight improved particle swarm optimization method

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Authors: Qun-Feng Zhang, Pan-Pan Yan, Jun Li, Jun-Qing Lei

Abstract:

Numerical investigation of hammershock propagation in the S-bend intake caused by engine surge has been conducted by using Improved Delayed Detach-Eddy Simulation (IDDES). The effects of surge signatures on hammershock characteristics are obtained. It was shown that once the hammershock is produced, it moves upward to the intake entrance quickly with constant speed, however, the strength of hammershock keeps increasing. Meanwhile, being influenced by the centrifugal force, the hammershock strength on the larger radius side is much larger. Hammershock propagation speed and strength are sensitive to the ramp upgradient of surge signature. A larger ramp up gradient results in higher propagation speed and greater strength. Nevertheless, ramp down profile of surge signature have no obvious effect on the propagation speed and strength of hammershock. Increasing the maximum value of surge signature leads to enhance in the intensity of hammershock, they approximately match quadratic function distribution law.

Keywords: Hammershock, IDDES, S-bend, surge signature.

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Authors: Ho-Jun Jo, Wook-Won Kim, Yong-Sung Kim, Jin-O Kim

Abstract:

The application of ESS (Energy Storage Systems) in the future grids has been the solution of the microgrid. However, high investment costs necessitate accurate modeling and control strategy of ESS to justify its economic viability and further underutilization. Therefore, the reasonable control strategy for ESS which is subjected to generator and usage helps to curtail the cost of investment and operation costs. The rated frequency in power system is decreased when the load is increasing unexpectedly; hence the thermal power is operated at the capacity of only its 95% for the Governor Free (GF) to adjust the frequency as reserve (5%) in practice. The ESS can be utilized with governor at the same time for the frequency response due to characteristic of its fast response speed and moreover, the cost of ESS is declined rapidly to the reasonable price. This paper presents the ESS control strategy to extend usage of the ESS taken account into governor’s ramp rate and reduce the governor’s intervention as well. All results in this paper are simulated by MATLAB.

Keywords: Micro grid, energy storage systems, ramp rate, control strategy.

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Authors: Ali H. Mahfouz, Hossam E. M.Sallam, Abdulwali Wazir, Hamod H. Kharezi

Abstract:

The soil profile at site of the bridge project includes soft fine grained soil layer located between 5.0 m to 11.0 m in depth, it has high water content, low SPT no., and low bearing capacity. The clay layer induces high settlement due to surcharge application of earth embankment at ramp T1, ramp T2, and ramp T3 especially at heights from 9m right 3m. Calculated settlement for embankment heights less than 3m may be accepted regarding Saudi Code for soil and foundation. The soil and groundwater at the project site comprise high contents of sulfates and chlorides of high aggressively on concrete and steel bars, respectively. Regarding results of the study, it has been recommended to use stone column piles or new technology named PCC piles as soil improvement to improve the bearing capacity of the weak layer. The new technology is cast in-situ thin wall concrete pipe piles (PCC piles), it has economically advantageous and high workability. The technology can save time of implementation and cost of application is almost 30% of other types of piles.

Keywords: Soft foundation soil, bearing capacity, bridge ramps, soil improvement, PCC piles.

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Authors: T. Tanitteerapan, E.Thanpo

Abstract:

This paper, a simple continuous conduction mode (CCM) pulse-width-modulated (PWM) controller for high power factor boost converters is introduced. The duty ratios were obtained by the comparison of a sensed signal from inductor current or switch current and a negative slope ramp carrier waveform in each switching period. Due to the proposed control requires only the inductor current or switch current sensor and the output voltage sensor, its circuit implementation was very simple. To verify the proposed control, the circuit experimentation of a 350 W boost converter with the proposed control was applied. From the results, the input current waveform was shaped to be closely sinusoidal, implying high power factor and low harmonics.

Keywords: High power factor converters, boost converters, low harmonic rectifiers, power factor correction, and current control.

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Authors: K. C. Meher, R. K. Swain, C. K. Chanda

Abstract:

This paper gives an intuition regarding glowworm swarm optimization (GSO) technique to solve dynamic economic dispatch (DED) problems of thermal generating units. The objective of the problem is to schedule optimal power generation of dedicated thermal units over a specific time band. In this study, Glowworm swarm optimization technique enables a swarm of agents to split into subgroup, exhibit simultaneous taxis towards each other and rendezvous at multiple optima (not necessarily equal) of a given multimodal function. The feasibility of the GSO method has been tested on ten-unit-test systems where the power balance constraints, operating limits, valve point effects, and ramp rate limits are taken into account. The results obtained by the proposed technique are compared with other heuristic techniques. The results show that GSO technique is capable of producing better results.

Keywords: Dynamic economic dispatch, Glowworm swarm optimization, Luciferin, Valve–point loading effect, Ramp rate limits.

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Authors: Achim Kampker, Kai Kreiskoether, Johannes Wagner, Sarah Fluchs

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The growing speed of innovation in related industries requires the automotive industry to adapt and increase release frequencies of new vehicle derivatives which implies a significant reduction of investments per vehicle and ramp-up times. Emerging markets in various parts of the world augment the currently dominating established main automotive markets. Local content requirements such as import tariffs on final products impede the accessibility of these micro markets, which is why in the future market exploitation will not be driven by pure sales activities anymore but rather by setting up local assembly units. The aim of this paper is to provide an overview of the concept of decentralized assembly and to discuss and critically assess some currently researched and crucial approaches in production technology. In order to determine the scope in which complementary mobile assembly can be profitable for manufacturers, a general cost model is set up and each cost driver is assessed with respect to varying levels of decentralization. One main result of the paper is that the presented approaches offer huge cost-saving potentials and are thus critical for future production strategies. Nevertheless, they still need to be further exploited in order for decentralized assembly to be profitable for companies. The optimal level of decentralization must, however, be specifically determined in each case and cannot be defined in general.

Keywords: Automotive assembly, e-mobility, production technology, small series assembly.

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Authors: S. Homrossukon, D. Aromstain

Abstract:

The simple methods used to plan and measure non patterned production system are developed from the basic definition of working efficiency. Processing time is assigned as the variable and used to write the equation of production efficiency. Consequently, such equation is extensively used to develop the planning method for production of interest using one-dimensional stock cutting problem. The application of the developed method shows that production efficiency and production planning can be determined effectively.

Keywords: Production Planning, Parallel Machine, Production Measurement, Cutting and Packing.

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Authors: M. R. Gholizadeh, N. Bhuiyan, M. Salari

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In the near future, companies will be increasingly forced to shift their activities along a new road in order to decrease the harmful effects of their design, production and after-life on our environment. Products must meet environmental standards to not only prevent penalties but to consider the sustainability for future generations. However, the most important factor that companies will face is selecting a reasonable strategy to maximize their profit. Thus, companies need to have precise forecast from their profit after design stage through Trade-off analysis. This paper is an attempt to introduce a mathematical model that considers effective factors that impact the total profit when products are designed for resource and energy efficiency or recyclability. The modification is according to different strategies based on a Cost-Volume-Profit model. Here, the cost structure consists of Recycling cost, Development cost, Ramp-up cost, Production cost, and Pollution cost. Also, the model shows the effect of implementation of design for recyclable on revenue structure through revenue of used parts and revenue of recycled materials. A numerical example is used to evaluate the proposed model. Results show that fulfillment of Green Product Development not only can reduce the environmental impact of products but also it will increase profit of company in long term.

Keywords: Green Product, Design for Environment, C-V-P Model, Trade-off analysis.

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Authors: Stefan Schmidt

Abstract:

Lean production (or lean management respectively) gained popularity in several waves. The last three decades have been filled with numerous attempts to apply these concepts in companies. However, this has only been partially successful. The roots of lean production can be traced back to Toyota-s just-in-time production. This concept, which according to Womack-s, Jones- and Roos- research at MIT was employed by Japanese car manufacturers, became popular under its international names “lean production", “lean-manufacturing" and was termed “Schlanke Produktion" in Germany. This contribution shows a review about lean production in Germany over the last thirty years: development, trial & error and implementation as well.

Keywords: Application, JIT, lean production, review, trial and error.

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Authors: R. Knizek, D. Karhankova

Abstract:

The production of nanofibers and the machinery for their production is a current issue. The pioneer, in the industrial production of nanofibers, is the machinery with the sales descriptions Nanospider^TM from the company Elmarco, which came into being in 2008. Most of the production facilities, like Nanospider^TM, use electrospinning. There are also other methods of industrial production of nanofibers, such as the centrifugal spinning process, which is used by FibeRio Technology Corporation. However, each method and machine has its advantages, but also disadvantages and that is the reason why a new machine called as Nanomachine, which eliminates the disadvantages of other production facilities producing nanofibers, has been developed.

Keywords: Nanomachine, nanospider, spinning slat, electrospinning.

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Authors: Ben Muenzberg, Prof. Peter Nyhuis

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The logistical requirements placed on industrial manufacturing companies are steadily increasing. In order to meet those requirements, a consistent and efficient concept is necessary for production control. Set up properly, production control offers considerable potential with respect to achieving the logistical targets. As experience with the many production control methods already in existence and their compatibility is, however, often inadequate, this article describes a systematic approach to the configuration of production control based on the Lödding model. This model enables production control to be set up individually to suit a company and the requirements. It therefore permits today-s demands regarding logistical performance to be met.

Keywords: Production, planning, control, configuration.

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Authors: G. Reinhart, J. Pohl

Abstract:

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: Susmita Sahoo, Madhumanti Datta, Rajib Kar

Abstract:

Fast delay estimation methods, as opposed to simulation techniques, are needed for incremental performance driven layout synthesis. On-chip inductive effects are becoming predominant in deep submicron interconnects due to increasing clock speed and circuit complexity. Inductance causes noise in signal waveforms, which can adversely affect the performance of the circuit and signal integrity. Several approaches have been put forward which consider the inductance for on-chip interconnect modelling. But for even much higher frequency, of the order of few GHz, the shunt dielectric lossy component has become comparable to that of other electrical parameters for high speed VLSI design. In order to cope up with this effect, on-chip interconnect has to be modelled as distributed RLCG line. Elmore delay based methods, although efficient, cannot accurately estimate the delay for RLCG interconnect line. In this paper, an accurate analytical delay model has been derived, based on first and second moments of RLCG interconnection lines. The proposed model considers both the effect of inductance and conductance matrices. We have performed the simulation in 0.18μm technology node and an error of as low as less as 5% has been achieved with the proposed model when compared to SPICE. The importance of the conductance matrices in interconnect modelling has also been discussed and it is shown that if G is neglected for interconnect line modelling, then it will result an delay error of as high as 6% when compared to SPICE.

Keywords: Delay Modelling; On-Chip Interconnect; RLCGInterconnect; Ramp Input; Damping; VLSI

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Authors: Tomas Duranik, Juraj Ruzbarsky, Markus Stopper

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CONWIP (constant work-in-process) as a pull production system have been widely studied by researchers to date. The CONWIP pull production system is an alternative to pure push and pure pull production systems. It lowers and controls inventory levels which make the throughput better, reduces production lead time, delivery reliability and utilization of work. In this article a CONWIP pull production system was simulated. It was simulated push and pull planning system. To compare these systems via a production planning system (PPS) game were adjusted parameters of each production planning system. The main target was to reduce the total WIP and achieve throughput and delivery reliability to minimum values. Data was recorded and evaluated. A future state was made for real production of plastic components and the setup of the two indicators with CONWIP pull production system which can greatly help the company to be more competitive on the market.

Keywords: CONWIP, constant work in process, delivery reliability, hybrid production planning, PPS.

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Authors: Pavel Vazan, Pavol Tanuska, Michal Kebisek

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The paper gives the pilot results of the project that is oriented on the use of data mining techniques and knowledge discoveries from production systems through them. They have been used in the management of these systems. The simulation models of manufacturing systems have been developed to obtain the necessary data about production. The authors have developed the way of storing data obtained from the simulation models in the data warehouse. Data mining model has been created by using specific methods and selected techniques for defined problems of production system management. The new knowledge has been applied to production management system. Gained knowledge has been tested on simulation models of the production system. An important benefit of the project has been proposal of the new methodology. This methodology is focused on data mining from the databases that store operational data about the production process.

Keywords: data mining, data warehousing, management of production system, simulation

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Authors: B. Fahimnia, L.H.S. Luong, R. M. Marian

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The Aggregate Production Plan (APP) is a schedule of the organization-s overall operations over a planning horizon to satisfy demand while minimizing costs. It is the baseline for any further planning and formulating the master production scheduling, resources, capacity and raw material planning. This paper presents a methodology to model the Aggregate Production Planning problem, which is combinatorial in nature, when optimized with Genetic Algorithms. This is done considering a multitude of constraints of contradictory nature and the optimization criterion – overall cost, made up of costs with production, work force, inventory, and subcontracting. A case study of substantial size, used to develop the model, is presented, along with the genetic operators.

Keywords: Aggregate Production Planning, Costs, and Optimization.

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Authors: R. Usubamatov, M. Z. Abdulmuin

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Automated production lines with so called 'hard structures' are widely used in manufacturing. Designers segmented these lines into sections by placing a buffer between the series of machine tools to increase productivity. In real production condition the capacity of a buffer system is limited and real production line can compensate only some part of the productivity losses of an automated line. The productivity of such production lines cannot be readily determined. This paper presents mathematical approach to solving the structure of section-based automated production lines by criterion of maximum productivity.

Keywords: optimization production line, productivity, sections

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Authors: Marco Kennemann, Steffen C. Eickemeyer, Peter Nyhuis

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An increasingly dynamic and complex environment poses huge challenges to production enterprises, especially with regards to logistics. The Logistic Operating Curve Theory, developed at the Institute of Production Systems and Logistics (IFA) of the Leibniz University of Hanover, is a recognized approach to describing logistic interactions, nevertheless, it reaches its limits when it comes to the dynamic aspects. In order to facilitate a timely and optimal Logistic Positioning a method is developed for quickly and reliably identifying dynamic processing states.

Keywords: Dynamics, Logistic Operating Curves, Production Logistics, Production Planning and Control

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Authors: Govind Sharan Dangayach, Himanshu Bhatt

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The paper attempts to overcome the fluctuations occurring in demand of the components in an automotive sector company. Resource and time being the strict constraints, the production is not able to match the pace of the fluctuating demand. So, we introduce some production schedules that help in meeting out the required demand. The merits and demerits of the approaches are also highlighted.

Keywords: Production scheduling, Demand rise, Capacity constrained resource (CCR), Overtime.

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Authors: G. Schuh, T. Potente, D. Kupke, S. Ivanescu

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As German companies roll out their standardized production systems to offshore manufacturing plants, they face the challenge of implementing them in different cultural environments. Studies show that the local adaptation is one of the key factors for a successful implementation. Thus the question arises of where the line between standardization and adaptation can be drawn. To answer this question the influence of culture on production systems is analysed in this paper. The culturally contingent components of production systems are identified. Also the contingency factors are classified according to their impact on the necessary adaptation changes and implementation effort. Culturally specific decision making, coordination, communication and motivation patterns require one-time changes in organizational and process design. The attitude towards rules requires more intense coaching and controlling. Lastly a framework is developed to depict standardization and adaption needs when transplanting production systems into different cultural environments.

Keywords: Culture, influence of national culture on production systems, lean production, production systems.

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Authors: J. Ranogajec, O. Rudic, S. Pasalic, S. Vucetic, D. Cjepa

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The paper involves a chain of activities from synthesis, establishment of the methodology for characterization and testing of novel protective materials through the pilot production and application on model supports. It summarizes the results regarding the development of the pilot production protocol for newly developed self-cleaning materials. The optimization of the production parameters was completed in order to improve the most important functional properties (mineralogy characteristics, particle size, self-cleaning properties and photocatalytic activity) of the newly designed nanocomposite material.

Keywords: Cultural heritage. Materials compatibility. Pilot production. Self-cleaning.

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Authors: F. Keller, G. Reinhart

Abstract:

The efficient and economic allocation of resources is one main goal in the field of production planning and control. Nowadays, a new variable gains in importance throughout the planning process: Energy. Energy-efficiency has already been widely discussed in literature, but with a strong focus on reducing the overall amount of energy used in production. This paper provides a brief systematic approach, how energy-supply-orientation can be used for an energy-cost-efficient production planning and thus combining the idea of energy-efficiency and energy-flexibility.

Keywords: Production planning and control, energy, efficiency, flexibility.

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Authors: Seung Woo Lee, So Jeong Nam, Jai-Kyung Lee

Abstract:

It can be said that the business sector is faced with a range of challenges–a rapidly changing business environment, an increase and diversification of customers- demands and the consequent need for quick response–for having in place flexible management and production info systems. As a matter of fact, many manufacturers have adopted production info management systems such as MES and ERP. Nevertheless, managers are having difficulties obtaining ever-changing production process information in real time, or responding quickly to any change in production related needs on the basis of such information. This is because they rely on poor production info systems which are not capable of providing real-time factory settings. If the manufacturer doesn-t have a capacity for collecting or digitalizing the 4 Ms (Man, Machine, Material, Method), which are resources for production, on a real time basis, it might to difficult to effectively maintain the information on production process. In this regard, this paper will introduce some new alternatives to the existing methods of collecting the 4 Ms in real time, which are currently comprise the production field.

Keywords: 4M, Acquisition of Data on shop-floor, Real-time machine interface

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Authors: S. Kreitlein, N. Eder, A. Syed-Khaja, J. Franke

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The importance of energy efficiency within the production processes increases steadily. For a comprehensive assessment of energy efficiency within the production process, unfortunately no tools exist or have been developed yet. Therefore the Institute for Factory Automation and Production Systems at the Friedrich-Alexander-University Erlangen-Nuremberg has developed two methods with the goal of achieving transparency and a quantitative assessment of energy efficiency namely EEV (Energy Efficiency Value) and EPE (Energetic Process Efficiency). This paper describes the basics and state-of-the-art as well as the developed approaches.

Keywords: Energy efficiency, energy efficiency value, energetic process efficiency, production.

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Authors: Sebastian Bertsch

Abstract:

In the past decades, the environment of production companies showed a permanent increase in dynamic and volatility in the form of demand fluctuations, new technologies or global crises. As a reaction to these new requirements, changeability of production systems came into attention. A changeable production system can adapt to these changes quickly and with little effort. Even though demand for changeable production exists for some time, the practical application is still insufficient.

To overcome this deficit, a three year research project at the Department of Production Systems and Logistics at the Leibniz University of Hanover/ Germany was initiated. As a result of this project, different concepts have been developed to design production changeable. An excerpt of the results will be presented in this paper. An eight step procedure will be presented to design the changeability of production logistics. This procedure has been applied at a German manufacturer of high demanding weighing machines. The developed procedure, their application in industry, as well as the major results of the application will be presented.

Keywords: Changeability, Change Drivers, Production Logistics.

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