Search results for: automated manufacturing system

Authors: Mijoh A. Gbededo, Kapila Liyanage, Ilias Oraifige

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Decision making for sustainable manufacturing design and management requires critical considerations due to the complexity and partly conflicting issues of economic, social and environmental factors. Although there are tools capable of assessing the combination of one or two of the sustainability factors, the frameworks have not adequately integrated all the three factors. Case study and review of existing simulation applications also shows the approach lacks integration of the sustainability factors. In this paper we discussed the development of a simulation based framework for support of a holistic assessment of sustainable manufacturing design and management. To achieve this, a strategic approach is introduced to investigate the strengths and weaknesses of the existing decision supporting tools. Investigation reveals that Discrete Event Simulation (DES) can serve as a rock base for other Life Cycle Analysis frameworks. Simio-DES application optimizes systems for both economic and competitive advantage, Granta CES EduPack and SimaPro collate data for Material Flow Analysis and environmental Life Cycle Assessment, while social and stakeholders’ analysis is supported by Analytical Hierarchy Process, a Multi-Criteria Decision Analysis method. Such a common and integrated framework creates a platform for companies to build a computer simulation model of a real system and assess the impact of alternative solutions before implementing a chosen solution.

Keywords: Discrete event simulation, life cycle sustainability analysis, manufacturing, sustainability.

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Authors: Dušan Kravec, Ondrej Staš, Marián Tolnay, Michal Bachratý

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This article gives a short preview of the new software created especially for palletizing process in automated production systems. Each chapter of this article is about problem solving in development of modules in Java programming language. First part describes structure of the software, its modules and data flow between them. Second part describes all deployment methods, which are implemented in the software. Next chapter is about twodimensional editor created for manipulation with objects in each layer of the load and gives calculations for collision control. Module of virtual reality used for three-dimensional preview and creation of the load is described in the fifth chapter. The last part of this article describes communication and data flow between control system of the robot, vision system and software.

Keywords: Palletizing, deployment methods, palletizing software, virtual reality in palletizing.

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Authors: A. Gruzdz, A. Ihnatowicz, J. Siddiqi, B. Akhgar

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MATCH project [1] entitle the development of an automatic diagnosis system that aims to support treatment of colon cancer diseases by discovering mutations that occurs to tumour suppressor genes (TSGs) and contributes to the development of cancerous tumours. The constitution of the system is based on a) colon cancer clinical data and b) biological information that will be derived by data mining techniques from genomic and proteomic sources The core mining module will consist of the popular, well tested hybrid feature extraction methods, and new combined algorithms, designed especially for the project. Elements of rough sets, evolutionary computing, cluster analysis, self-organization maps and association rules will be used to discover the annotations between genes, and their influence on tumours [2]-[11]. The methods used to process the data have to address their high complexity, potential inconsistency and problems of dealing with the missing values. They must integrate all the useful information necessary to solve the expert's question. For this purpose, the system has to learn from data, or be able to interactively specify by a domain specialist, the part of the knowledge structure it needs to answer a given query. The program should also take into account the importance/rank of the particular parts of data it analyses, and adjusts the used algorithms accordingly.

Keywords: Bioinformatics, gene expression, ontology, selforganizingmaps.

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Authors: Turan Erman Erkan

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Business Process Reengineering (BPR) is an essential tool before an information system project implementation. Enterprise Resource Planning (ERP) projects definitely require the standardization and fixation of business processes from customer order to shipment. Therefore, ERP implementations are well proven to be coupled with BPR, although the extend and timing of BPR with respect to ERP implementation differ. This study aims at analyzing the effects of BPR on ERP implementation success. Basing on two Turkish ERP implementations in pharmaceutical sector, a comparative study is performed. One of the ERP implementations took place after a BPR implementation, whereas the other implementation was without a prior BPR application. Both implementations have been realized with the same consultant team, the case with prior BPR implementation going live first. The results of the case study reveal that if business processes are not optimized and improved before an ERP implementation, ERP live system would face with disharmony problems of processes and processes automated by ERP. This suggests a definite precedence relationship between BPR and ERP applications

Keywords: Business Process Reengineering, Enterprise Resource Planning

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Authors: C. Tung, P.-L. Tso

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This paper presents a complete procedure for tool path planning and blade machining in 5-axis manufacturing. The actual cutting contact and cutter locations can be determined by lead and tilt angles. The tool path generation is implemented by piecewise curved approximation and chordal deviation detection. An application about drive surface method promotes flexibility of tool control and stability of machine motion. A real manufacturing process is proposed to separate the operation into three regions with five stages and to modify the local tool orientation with an interactive algorithm.

Keywords: 5-axis machining, tool orientation, lead and tilt angles, tool path generation.

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Authors: Alessandro Bevilacqua, Alessandro Gherardi, Filippo Piccinini

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Image mosaicing techniques are usually employed to offer researchers a wider field of view of microscopic image of biological samples. a mosaic is commonly achieved using automated microscopes and often with one “color" channel, whether it refers to natural or fluorescent analysis. In this work we present a method to achieve three subsequent mosaics of the same part of a stem cell culture analyzed in phase contrast and in fluorescence, with a common non-automated inverted microscope. The mosaics obtained are then merged together to mark, in the original contrast phase images, nuclei and cytoplasm of the cells referring to a mosaic of the culture, rather than to single images. The experiments carried out prove the effectiveness of our approach with cultures of cells stained with calcein (green/cytoplasm and nuclei) and hoechst (blue/nuclei) probes.

Keywords: Microscopy, image mosaicing, fluorescence, stem cells.

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Authors: Williams S. Ebhota, Virginia Chika Ebhota, Samuel A. Ilupeju

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Agriculture employs about three-quarter of Nigeria's workforce and yet food sufficiency is a challenge in the country. This is largely due to poor and outdated pre-harvest and post-harvest farming practices. The land fallow system is still been practised as fertiliser production in the country is grossly inadequate and expensive. The few available post-harvest processing facilities are faced with ageing and are inefficient. Also, use of modern processing equipment is limited by farmers' lack of fund, adequate capacity to operate and maintain modern farming equipment. This paper, therefore, examines key barriers to agricultural products processing equipment in the country. These barriers include over-dependence on foreign technologies and expertise; poor and inadequate manufacturing infrastructure; and lack of political will by political leaders; lack of funds; and lack of adequate technical skills. This paper, however, sees the increase in the domestic manufacturing of pre-harvest and post-harvest machinery and equipment through reverse engineering approach as a key to food production sufficiency in Nigeria.

Keywords: Agricultural machinery, domestic manufacturing, forward engineering, production reverse engineering, technology.

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Authors: T. Ahilan, V. Aswin Adityan, S. Kailash

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UAV’s are small remote operated or automated aerial surveillance systems without a human pilot aboard. UAV’s generally finds its use in military and special operation application, a recent growing trend in UAV’s finds its application in several civil and nonmilitary works such as inspection of power or pipelines. The objective of this paper is the augmentation of a UAV in order to replace the existing expensive sonar (Sound Navigation And Ranging) based equipment amongst small scale fisherman, for whom access to sonar equipment are restricted due to limited economic resources. The surveillance equipment’s present in the UAV will relay data and GPS (Global Positioning System) location onto a receiver on the fishing boat using RF signals, using which the location of the schools of fishes can be found. In addition to this, an emergency beacon system is present for rescue operations and drone recovery.

Keywords: GPS, RF signals, School of fish, Sonar, Surveillance UAV, Video stream.

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Authors: S. B. Jaju, R. R. Lakhe

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Quality costs are the costs associated with preventing, finding, and correcting defective work. Since the main language of corporate management is money, quality-related costs act as means of communication between the staff of quality engineering departments and the company managers. The objective of quality engineering is to minimize the total quality cost across the life of product. Quality costs provide a benchmark against which improvement can be measured over time. It provides a rupee-based report on quality improvement efforts. It is an effective tool to identify, prioritize and select quality improvement projects. After reviewing through the literature it was noticed that a simplified methodology for data collection of quality cost in a manufacturing industry was required. The quantified standard methodology is proposed for collecting data of various elements of quality cost categories for manufacturing industry. Also in the light of research carried out so far, it is felt necessary to standardise cost elements in each of the prevention, appraisal, internal failure and external failure costs. . Here an attempt is made to standardise the various cost elements applicable to manufacturing industry and data is collected by using the proposed quantified methodology. This paper discusses the case study carried in luggage manufacturing industry.

Keywords: Quality Costs, PAF model, quantified methodology, Case study.

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Authors: G. F. Guimarães, A. R. de Faria, R. R. Rego, A. L. R. D’Oliveira

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One of the most relevant phenomena in manufacturing is the residual stress state development through the manufacturing chain. In most cases, the residual stresses have their origin in the heterogenous plastification produced by the processes. Although a few manufacturing processes have been successfully approached by numerical modeling, there is still lack of understanding on how these processes' interactions will affect the final stress state. The objective of this work is to analyze the effect of the grinding procedure on the residual stress state generated by a quasi-static indentation. The model consists in a simplified approach of shot peening, modeling four cases with variations in indenter size and force. This model was validated through topography, measured by optical 3D focus-variation. The indentation model configured with two loads was then exposed to two grinding procedures and the result was analyzed. It was observed that the grinding procedure will have a significant effect on the stress state.

Keywords: plasticity, residual stress, finite element method, manufacturing

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Authors: Javaid Butt, Habtom Mebrahtu, Hassan Shirvani

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The paper presents an additive manufacturing process for the production of metal and composite parts. It is termed as composite metal foil manufacturing and is a combination of laminated object manufacturing and brazing techniques. The process has been described in detail and is being used to produce dissimilar aluminum to copper foil single lap joints. A three dimensional finite element model has been developed to study the thermo-mechanical characteristics of the dissimilar Al/Cu single lap joint. The effects of thermal stress and strain have been analyzed by carrying out transient thermal analysis on the heated plates used to join the two 0.1mm thin metal foils. Tensile test has been carried out on the foils before joining and after the single Al/Cu lap joints are made, they are subjected to tensile lap-shear test to analyze the effect of heat on the foils. The analyses are designed to assess the mechanical integrity of the foils after the brazing process and understand whether or not the heat treatment has an effect on the fracture modes of the produced specimens.

Keywords: Brazing, Laminated Object Manufacturing, Tensile Lap-Shear Test, Thermo-Mechanical Analysis.

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Authors: Dahir A. Ga'al, Wardah Zainal Abidin

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Policy management in organizations became rising issue in the last decade. It’s because of today’s regulatory requirements in the organizations. To manage policies in large organizations is an imperative work. However, major challenges facing organizations in the last decade is managing all the policies in the organization and making them an active documents rather than simple (inactive) documents stored in computer hard drive or on a shelf. Because of this challenge, organizations need policy management program. This policy management program can be either manual or automated. This paper presents suggestions towards managing policies in organizations. As well as possible policy management solution or program to be utilized, manual or automated. The research first examines the models and frameworks used for managing policies from various perspectives in the literature of the research area/domain. At the end of this paper, a policy management framework is proposed for managing enterprise policies effectively and in a simplified manner.

Keywords: Policy, policy management, policy management program, policy repository.

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Authors: R. Clancy, M. Ahern, D. O’Sullivan, K. Bruton

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The manufacturing industry is currently undergoing a digital transformation as part of the mega-trend Industry 4.0. As part of this phase of the industrial revolution, traditional manufacturing processes are being combined with digital technologies to achieve smarter and more efficient production. To successfully digitally transform a manufacturing facility, the processes must first be digitized. This is the conversion of information from an analogue format to a digital format. The objective of this study was to explore the research area of digitizing manufacturing data as part of the worldwide paradigm, Industry 4.0. The formal methodology of a systematic mapping study was utilized to capture a representative sample of the research area and assess its current state. Specific research questions were defined to assess the key benefits and limitations associated with the digitization of manufacturing data. Research papers were classified according to the type of research and type of contribution to the research area. Upon analyzing 54 papers identified in this area, it was noted that 23 of the papers originated in Germany. This is an unsurprising finding as Industry 4.0 is originally a German strategy with supporting strong policy instruments being utilized in Germany to support its implementation. It was also found that the Fraunhofer Institute for Mechatronic Systems Design, in collaboration with the University of Paderborn in Germany, was the most frequent contributing Institution of the research papers with three papers published. The literature suggested future research directions and highlighted one specific gap in the area. There exists an unresolved gap between the data science experts and the manufacturing process experts in the industry. The data analytics expertise is not useful unless the manufacturing process information is utilized. A legitimate understanding of the data is crucial to perform accurate analytics and gain true, valuable insights into the manufacturing process. There lies a gap between the manufacturing operations and the information technology/data analytics departments within enterprises, which was borne out by the results of many of the case studies reviewed as part of this work. To test the concept of this gap existing, the researcher initiated an industrial case study in which they embedded themselves between the subject matter expert of the manufacturing process and the data scientist. Of the papers resulting from the systematic mapping study, 12 of the papers contributed a framework, another 12 of the papers were based on a case study, and 11 of the papers focused on theory. However, there were only three papers that contributed a methodology. This provides further evidence for the need for an industry-focused methodology for digitizing and analyzing manufacturing data, which will be developed in future research.

Keywords: Analytics, digitization, industry 4.0, manufacturing.

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Authors: Andrus Pedai, Igor Astrov

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In modern telecommunications industry, demand & supply chain management (DSCM) needs reliable design and versatile tools to control the material flow. The objective for efficient DSCM is reducing inventory, lead times and related costs in order to assure reliable and on-time deliveries from manufacturing units towards customers. In this paper the multi-rate expert system based methodology for developing simulation tools that would enable optimal DSCM for multi region, high volume and high complexity manufacturing environment was proposed.

Keywords: Demand & supply chain management, expert systems, inventory control, multi-rate control, performance metrics.

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Authors: Mijoh A. Gbededo, Kapila Liyanage, Sabuj Mallik

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The emerging approaches to sustainable manufacturing are considered to be solution-oriented with the aim of addressing the environmental, economic and social issues holistically. However, the analysis of the interdependencies amongst the three sustainability dimensions has not been fully captured in the literature. In a recent review of approaches to sustainable manufacturing, two categories of techniques are identified: 1) Sustainable Product Development (SPD), and 2) Sustainability Performance Assessment (SPA) techniques. The challenges of the approaches are not only related to the arguments and misconceptions of the relationships between the techniques and sustainable development but also to the inability to capture and integrate the three sustainability dimensions. This requires a clear definition of some of the approaches and a road-map to the development of a holistic approach that supports sustainability decision-making. In this context, eco-innovation, social impact assessment, and life cycle sustainability analysis play an important role. This paper deployed an integrative approach that enabled amalgamation of sustainable manufacturing approaches and the theories of reciprocity and motivation into a holistic simulation-based impact analysis framework. The findings in this research have the potential to guide sustainability analysts to capture the aspects of the three sustainability dimensions into an analytical model. Additionally, the research findings presented can aid the construction of a holistic simulation model of a sustainable manufacturing and support effective decision-making.

Keywords: Life cycle sustainability analysis, sustainable manufacturing, sustainability performance assessment, sustainable product development.

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Authors: Kittipong Tissayakorn, Fumio Akagi, Yu Song

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Manufacturers have been exploring innovative strategies to achieve and sustain competitive advantages as they face a new era of intensive global competition. Such strategy is known as Supply Chain Management (SCM), which has gained a tremendous amount of attention from both researchers and practitioners over the last decade. Supply chain management (SCM) is considered as the most popular operating strategy for improving organizational competitiveness in the twenty-first century. It has attracted a lot of attention recently due to its role involving all of the activities in industrial organizations, ranging from raw material procurement to final product delivery to customers. Well-designed supply chain systems can substantially improve efficiency and product quality, and eventually enhance customer satisfaction and profitability. In this paper, a manufacturing engineering perspective on supply chain integration is presented. Research issues discussed include the product and process design for the supply chain, design evaluation of manufacturing in the supply chain, agent-based techniques for supply chain integration, intelligent information for sharing across the supply chain, and a development of standards for product, process, and production data exchange to facilitate electronic commerce. The objective is to provide guidelines and references for manufacturing engineers and researchers interested in supply chain integration.

Keywords: Supply Chain, Supply Chain Management, Supply Chain Integration, Manufacturing Industries.

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Authors: C. Senanayake, S. Veera Ragavan

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Warehousing is commonly used in factories for the storage of products until delivery of orders. As the amount of products stored increases it becomes tedious to be carried out manually. In recent years, the manual storing has converted into fully or partially computer controlled systems, also known as Automated Storage and Retrieval Systems (AS/RS). This paper discusses an ASRS system, which was designed such that the best storage location for the products is determined by utilizing a fuzzy control system. The design maintains the records of the products to be/already in store and the storage/retrieval times along with the availability status of the storage locations. This paper discusses on the maintenance of the above mentioned records and the utilization of the concept of fuzzy logic in order to determine the optimum storage location for the products. The paper will further discuss on the dynamic splitting and merging of the storage locations depending on the product sizes.

Keywords: ASRS, fuzzy control systems, MySQL database, dynamic splitting and merging.

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Authors: T. P. Lu, B. N. Hwang, T. Z. Liou, Y. L. Lin

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Developing a supply chain management (SCM) system is costly, but important. However, because of its complicated nature, not many of such projects are considered successful. Few research publications directly relate to key success factors (KSFs) for implementing a SCM system. Motivated by the above, this research proposes a hierarchy of KSFs for SCM system implementation in the semiconductor industry by using a two-step approach. First, the literature review indicates the initial hierarchy. The second step includes a focus group approach to finalize the proposed KSF hierarchy by extracting valuable experiences from executives and managers that actively participated in a project, which successfully establish a seamless SCM integration between the world's largest semiconductor foundry manufacturing company and the world's largest assembly and testing company. Future project executives may refer the resulting KSF hierarchy as a checklist for SCM system implementation in semiconductor or related industries.

Keywords: Focus group, key success factors, supply chain management, semiconductor industry.

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Authors: Jean-Pierre Dubois, Jihad S. Daba, H. Karam, J. Abdallah

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Tsunami early detection and warning systems have proved to be of ultimate importance, especially after the destructive tsunami that hit Japan in March 2012. Such systems are crucial to inform the authorities of any risk of a tsunami and of the degree of its danger in order to make the right decision and notify the public of the actions they need to take to save their lives. The purpose of this research is to enhance existing tsunami detection and warning systems. We first propose an automated and miniaturized model of an early tsunami detection and warning system. The model for the operation of a tsunami warning system is simulated using the data acquisition toolbox of Matlab and measurements acquired from specified internet pages due to the lack of the required real-life sensors, both seismic and hydrologic, and building a graphical user interface for the system. In the second phase of this work, we implement various satellite image filtering schemes to enhance the acquired synthetic aperture radar images of the tsunami affected region that are masked by speckle noise. This enables us to conduct a post-tsunami damage extent study and calculate the percentage damage. We conclude by proposing improvements to the existing telecommunication infrastructure of existing warning tsunami systems using a migration to IP-based networks and fiber optics links.

Keywords: Detection, GIS, GSN, GTS, GPS, speckle noise, synthetic aperture radar, tsunami, wiener filter.

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Authors: Yuan-Jye Tseng, Yen-Jung Wang

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A product development for green logistics model using the fuzzy analytic network process method is presented for evaluating the relationships among the product design, the manufacturing activities, and the green supply chain. In the product development stage, there can be alternative ways to design the detailed components to satisfy the design concept and product requirement. In different design alternative cases, the manufacturing activities can be different. In addition, the manufacturing activities can affect the green supply chain of the components and product. In this research, a fuzzy analytic network process evaluation model is presented for evaluating the criteria in product design, manufacturing activities, and green supply chain. The comparison matrices for evaluating the criteria among the three groups are established. The total relational values between the three groups represent the relationships and effects. In application, the total relational values can be used to evaluate the design alternative cases for decision-making to select a suitable design case and the green supply chain. In this presentation, an example product is illustrated. It shows that the model is useful for integrated evaluation of design and manufacturing and green supply chain for the purpose of product development for green logistics.

Keywords: Supply chain management, green supply chain, product development for logistics, fuzzy analytic network process.

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Authors: Qi Xiu, Hiromu Hota, Yohsuke Ishii, Takuya Oda

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Recently, collectable manufacturing data are rapidly increasing. On the other hand, mega recall is getting serious as a social problem. Under such circumstances, there are increasing needs for preventing mega recalls by defect analysis such as root cause analysis and abnormal detection utilizing manufacturing data. However, the time to classify strings in manufacturing data by traditional method is too long to meet requirement of quick defect analysis. Therefore, we present String Length Distribution Classification method (SLDC) to correctly classify strings in a short time. This method learns character features, especially string length distribution from Product ID, Machine ID in BOM and asset list. By applying the proposal to strings in actual manufacturing data, we verified that the classification time of strings can be reduced by 80%. As a result, it can be estimated that the requirement of quick defect analysis can be fulfilled.

Keywords: Data quality, feature selection, probability distribution, string classification, string length.

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Authors: M. M. Islam, Rajib K. Saha, Abdullah A. Amin, M. Z. Haq

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The autonomous mobile robot was designed and implemented which was capable of navigating in the industrial environments and did a job of picking objects from variable height and delivering it to another location following a predefined trajectory. In developing country like Bangladesh industrial robotics is not very prevalent yet, due to the high installation cost. The objective of this project was to develop an autonomous mobile robot for industrial application using the available resources in the local market at lower manufacturing cost. The mechanical system of the robot was comprised of locomotion, gripping and elevation system. Grippers were designed to grip objects of a predefined shape. Cartesian elevation system was designed for vertical movement of the gripper. PIC18F452 microcontroller was the brain of the control system. The prototype autonomous robot was fabricated for relatively lower load than the industry and the performance was tested in a virtual industrial environment created within the laboratory to realize the effectiveness.

Keywords: Industrial application, autonomous mobile robot, appropriate technology.

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Authors: Adnan A. Ugla, Hassan J. Khaudair, Ahmed R. J. Almusawi

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Shaped Metal Deposition (SMD) in additive layered manufacturing technique is a promising alternative to traditional manufacturing used for manufacturing large, expensive metal components with complex geometry in addition to producing free structures by building materials in a layer by layer technique. The present paper is a comprehensive review of the literature and the latest rapid manufacturing technologies of the SMD technique. The aim of this paper is to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniques especially those associated with the cold wire feed. The intent of this study is to review the literature presented on metal deposition processes and their classifications, including SMD process using Wire + Arc Additive Manufacturing (WAAM) which divides into wire + tungsten inert gas (TIG), metal inert gas (MIG), or plasma. This literary research presented covers extensive details on bead geometry, process parameters and heat input or arc energy resulting from the deposition process in both cases MIG and Tandem-MIG in SMD process. Furthermore, SMD may be done using Single Wire-MIG (SW-MIG) welding and SMD using Double Wire-MIG (DW-MIG) welding. The present review shows that the method of deposition of metals when using the DW-MIG process can be considered a distinctive and low-cost method to produce large metal components due to high deposition rates as well as reduce the input of high temperature generated during deposition and reduce the distortions. However, the accuracy and surface finish of the MIG-SMD are less as compared to electron and laser beam.

Keywords: Shaped metal deposition, additive manufacturing, double-wire feed, cold feed wire.

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Authors: Nassima Cheikh, Abdelmadjid Cheikh, Said Hamou

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The objective of this work which is based on the approach of simultaneous engineering is to contribute to the development of a CIM tool for the synthesis of functional design dimensions expressed by average values and tolerance intervals. In this paper, the dispersions method known as the Δl method which proved reliable in the simulation of manufacturing dimensions is used to develop a methodology for the automation of the simulation. This methodology is constructed around three procedures. The first procedure executes the verification of the functional requirements by automatically extracting the functional dimension chains in the mechanical sub-assembly. Then a second procedure performs an optimization of the dispersions on the basis of unknown variables. The third procedure uses the optimized values of the dispersions to compute the optimized average values and tolerances of the functional dimensions in the chains. A statistical and cost based approach is integrated in the methodology in order to take account of the capabilities of the manufacturing processes and to distribute optimal values among the individual components of the chains.

Keywords: functional tolerances, manufacturing dispersions, simulation, CIM.

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Authors: Luis Gracia, Carlos Perez-Vidal, Carlos Gracia

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This paper presents the theoretical background and the real implementation of an automated computer system to introduce machine vision in flower, fruit and vegetable processing for recollection, cutting, packaging, classification, or fumigation tasks. The considerations and implementation issues presented in this work can be applied to a wide range of varieties of flowers, fruits and vegetables, although some of them are especially relevant due to the great amount of units that are manipulated and processed each year over the world. The computer vision algorithms developed in this work are shown in detail, and can be easily extended to other applications. A special attention is given to the electromagnetic compatibility in order to avoid noisy images. Furthermore, real experimentation has been carried out in order to validate the developed application. In particular, the tests show that the method has good robustness and high success percentage in the object characterization.

Keywords: Image processing, Vision system, Automation

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Authors: Nisachon Mawai, Jeerapat Ngaoprasertwong

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This study reports the implementation of Good Manufacturing Practice (GMP) in a polycarbonate film processing plant. The implementation of GMP took place with the creation of a multidisciplinary team. It was carried out in four steps: conduct gap assessment, create gap closure plan, close gaps, and follow up the GMP implementation. The basis for the gap assessment is the guideline for GMP for plastic materials and articles intended for Food Contact Material (FCM), which was edited by Plastic Europe. The effective results of the GMP implementation in this study showed 100% completion of gap assessment. The key success factors for implementing GMP in production process are the commitment, intention and support of top management.

Keywords: Implementation, Good Manufacturing Practice, Polycarbonate Film, Food Contact Materials.

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Authors: George Eleftherakis, Petros Kefalas, Anna Sotiriadou, Evangelos Kehris

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Recent advances in both the testing and verification of software based on formal specifications of the system to be built have reached a point where the ideas can be applied in a powerful way in the design of agent-based systems. The software engineering research has highlighted a number of important issues: the importance of the type of modeling technique used; the careful design of the model to enable powerful testing techniques to be used; the automated verification of the behavioural properties of the system; the need to provide a mechanism for translating the formal models into executable software in a simple and transparent way. This paper introduces the use of the X-machine formalism as a tool for modeling biology inspired agents proposing the use of the techniques built around X-machine models for the construction of effective, and reliable agent-based software systems.

Keywords: Biology inspired agent, formal methods, x-machines.

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Authors: K. K. Starkov, A. Y. Pogromsky, I. J. B. F. Adan, J. E. Rooda

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In this paper we present our results on the performance analysis of a multi-product manufacturing line. We study the influence of external perturbations, intermediate buffer content and the number of manufacturing stages on the production tracking error of each machine in the multi-product line operated under a surplusbased production control policy. Starting by the analysis of a single machine with multiple production stages (one for each product type), we provide bounds on the production error of each stage. Then, we extend our analysis to a line of multi-stage machines, where similarly, bounds on each production tracking error for each product type, as well as buffer content are obtained. Details on performance of the closed-loop flow line model are illustrated in numerical simulations.

Keywords: Flexible manufacturing systems, tracking systems, discrete time systems, production control, boundary conditions.

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Authors: Jasna Prester, Najla Podrug, Davor Filipović

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Manufacturing companies invest a significant amount of sales into material resources for production. In our sample, 58% of sales is used for manufacturing inputs, while only 24% of sales is used for salaries. This means that if a company is looking to reduce costs, the greater potential is in reduction of material costs than downsizing. This research shows that manufacturing companies in Croatia did realize material savings in last three years. It is also shown by which technologies they achieved materials cost savings. Through literature research, we found research gap as to which technologies reduce material consumption. As methodology of research four regression analyses are used to prove our findings.

Keywords: Croatia, materials savings strategies, technologies, return on sales.

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Authors: Zsolt János Viharos, Krisztián Balázs Kis, Imre Paniti, Gábor Belső, Péter Németh, János Farkas

Abstract:

The paper presents the results and industrial applications in the production setup period estimation based on industrial data inherited from the field of polymer cutting. The literature of polymer cutting is very limited considering the number of publications. The first polymer cutting machine is known since the second half of the 20th century; however, the production of polymer parts with this kind of technology is still a challenging research topic. The products of the applying industrial partner must met high technical requirements, as they are used in medical, measurement instrumentation and painting industry branches. Typically, 20% of these parts are new work, which means every five years almost the entire product portfolio is replaced in their low series manufacturing environment. Consequently, it requires a flexible production system, where the estimation of the frequent setup periods' lengths is one of the key success factors. In the investigation, several (input) parameters have been studied and grouped to create an adequate training information set for an artificial neural network as a base for the estimation of the individual setup periods. In the first group, product information is collected such as the product name and number of items. The second group contains material data like material type and colour. In the third group, surface quality and tolerance information are collected including the finest surface and tightest (or narrowest) tolerance. The fourth group contains the setup data like machine type and work shift. One source of these parameters is the Manufacturing Execution System (MES) but some data were also collected from Computer Aided Design (CAD) drawings. The number of the applied tools is one of the key factors on which the industrial partners’ estimations were based previously. The artificial neural network model was trained on several thousands of real industrial data. The mean estimation accuracy of the setup periods' lengths was improved by 30%, and in the same time the deviation of the prognosis was also improved by 50%. Furthermore, an investigation on the mentioned parameter groups considering the manufacturing order was also researched. The paper also highlights the manufacturing introduction experiences and further improvements of the proposed methods, both on the shop floor and on the quotation preparation fields. Every week more than 100 real industrial setup events are given and the related data are collected.

Keywords: Artificial neural network, low series manufacturing, polymer cutting, setup period estimation.

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