Search results for: modular factory systems

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

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

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

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Authors: Peter Burggräf, Moritz Krunke, Hanno Voet

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

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

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Authors: E. Farjami, La. Mohammadzadeh Afshar, Li. Mohammadzade Afshar, A. Taran

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Nowadays, flexibility introduced as a modern technology in furniture systems especially in interior planning design. According to results, the most important impact of these systems can be seen on open plan design that makes workspaces comfortable and increases the productivity of employees besides making good relationship between them. Briefly, there are some factors along with new systems in furniture design help create inappropriate space to make working better and easier while it has modular planning organization. It brings about some approaches to have a successful space for open offices with modular design and flexible furniture systems. These approaches have been investigated in open and close offices at Eastern Mediterranean University (EMU) in Famagusta, Cyprus, using information extracted from questionnaires.

Keywords: Flexibility, Flexible Furniture, Modular design, Open offices, Modular furniture systems.

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Authors: Kyung-Suk Choi, Hyung-Joon Kim

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Modular structural systems are constructed using a method that they are assembled with prefabricated unit modular frames on-site. This provides a benefit that can significantly reduce building construction time. The structural design is usually carried out under the assumption that their load-carrying mechanism is similar to that of traditional steel moment-resisting systems. However, both systems are different in terms of beam-column connection details which may strongly influence the lateral structural behavior. Specially, the presence of access holes in a beam-column joint of a unit modular frame could cause undesirable failure during strong earthquakes. Therefore, this study carried out finite element analyses (FEMs) of unit modular frames to investigate the cyclic behavior of beam-column joints with the access holes. Analysis results show that the unit modular frames present stable cyclic response with large deformation capacities and their joints are classified into semi-rigid connections even if there are access holes.

Keywords: Unit modular frame, steel moment connection, nonlinear analytical model, moment-rotation relation, access holes.

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

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

Keywords: economic efficiency, holistic evaluation, factory planning

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

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

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

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Authors: Rupali Verma, Maitreyee Dutta, Renu Vig

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Encryption and decryption in RSA are done by modular exponentiation which is achieved by repeated modular multiplication. Hence efficiency of modular multiplication directly determines the efficiency of RSA cryptosystem. This paper designs a Modified Montgomery Modular Multiplication in which addition of operands is computed by 4:2 compressor. The basic logic operations in addition are partitioned over two iterations such that parallel computations are performed. This reduces the critical path delay of proposed Montgomery design. The proposed design and RSA are implemented on Virtex 2 and Virtex 5 FPGAs. The two factors partitioning and parallelism have improved the frequency and throughput of proposed design.

Keywords: RSA, Montgomery modular multiplication, 4:2 compressor, FPGA.

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Authors: Dennis Gossmann, Habil Peter Nyhuis

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

Keywords: Changeability, human resources, learning factory.

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Authors: Ivan C. Mustakerov, Daniela I. Borissova

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The paper proposes an approach for design of modular systems based on original technique for modeling and formulation of combinatorial optimization problems. The proposed approach is described on the example of personal computer configuration design. It takes into account the existing compatibility restrictions between the modules and can be extended and modified to reflect different functional and users- requirements. The developed design modeling technique is used to formulate single objective nonlinear mixedinteger optimization tasks. The practical applicability of the developed approach is numerically tested on the basis of real modules data. Solutions of the formulated optimization tasks define the optimal configuration of the system that satisfies all compatibility restrictions and user requirements.

Keywords: Constrained discrete combinatorial choice, modular systems design, optimization problem, PC configuration.

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

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

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

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Authors: Thaniya Kaosol, Sirinthrar Wandee

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

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

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Authors: Seung-Kyung Kye, Young-Hyo Son, Jin-Woong Choi, Dooyong Cho, Sun-Kyu Park

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Recently in the field of bridges that are newly built or repaired, fast construction is required more than ever. For these reasons, precast prefabricated bridge that enables rapid construction is actively discussed and studied today. In South Korea, it is called modular bridge. Cross beam is an integral component of modular bridge. It functions for load distribution, reduction of bending moment, resistance of horizontal strength on lateral upper structure. In this study, the structural characteristics of domestic and foreign cross beam types were compared. Based on this, alternative cross beam connection types suitable for modular bridge were selected. And bulb-T girder specimens were fabricated with each type of connection. The behavior of each specimen was analyzed under static loading, and cross beam connection type which is expected to be best suited to modular bridge proposed.

Keywords: Bulb-T girder, Cross beam, Modular bridge.

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Authors: Marco Ryll, Svetan Ratchev

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

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

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Authors: Muhammad Safi, Abdul Manan

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In recent years, research in aircraft avionics systems (i.e., radars and antennas) has grown revolutionary. Aircraft technology is experiencing an increasing inclination from all mechanical to all electrical aircraft, with the introduction of inhabitant air vehicles and drone taxis over the last few years. This develops an overriding need to summarize the history, latest trends, and future development in aircraft avionics research for a better understanding and development of new technologies in the domain of avionics systems. This paper focuses on the future trends in antennas and phased arrays for avionics systems. Along with the general overview of the future avionics trend, this work describes the review of around 50 high-quality research papers on aircraft communication systems. Electric-powered aircrafts have been a hot topic in the modern aircraft world. Electric aircrafts have supremacy over their conventional counterparts. Due to increased drone taxi and urban air mobility, fast and reliable communication is very important, so concepts of Broadband Integrated Digital Avionics Information Exchange Networks (B-IDAIENs) and Modular Avionics are being researched for better communication of future aircraft. A Ku-band phased array antenna based on a modular design can be used in a modular avionics system. Furthermore, integrated avionics is also emerging research in future avionics. The main focus of work in future avionics will be using integrated modular avionics and infra-red phased array antennas, which are discussed in detail in this paper. Other work such as reconfigurable antennas and optical communication, are also discussed in this paper. The future of modern aircraft avionics would be based on integrated modulated avionics and small artificial intelligence-based antennas. Optical and infrared communication will also replace microwave frequencies.

Keywords: AI, avionics systems, communication, electric aircrafts, Infra-red, integrated avionics, modular avionics, phased array, reconfigurable antenna, UAVs.

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Authors: M. Gregor, J. Polcar, P. Horejsi, M. Simon

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Machine visualization is an area of interest with fast and progressive development. We present a method of machine visualization which will be applicable in real industrial conditions according to current needs and demands. Real factory data were obtained in a newly built research plant. Methods described in this paper were validated on a case study. Input data were processed and the virtual environment was created. The environment contains information about dimensions, structure, disposition, and function. Hardware was enhanced by modular machines, prototypes, and accessories. We added functionalities and machines into the virtual environment. The user is able to interact with objects such as testing and cutting machines, he/she can operate and move them. Proposed design consists of an environment with two degrees of freedom of movement. Users are in touch with items in the virtual world which are embedded into the real surroundings. This paper describes development of the virtual environment. We compared and tested various options of factory layout virtualization and visualization. We analyzed possibilities of using a 3D scanner in the layout obtaining process and we also analyzed various virtual reality hardware visualization methods such as: Stereoscopic (CAVE) projection, Head Mounted Display (HMD) and augmented reality (AR) projection provided by see-through glasses.

Keywords: Augmented reality, spatial scanner, virtual environment, virtual reality.

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Authors: J. Luebkemann, P. Nyhuis

Abstract:

Nowadays companies are facing an increasing turbulent environment. It is more and more important to react fast on changes to stay competitive. But not only the technology has to be adaptable; also the frame conditions for the production have to adapt as fast as the other elements of a manufacturing company. Therefore, the Institute of Production Systems and Logistics of the Leibniz University of Hanover has implemented a research project to describe and develop changeable organizational structures. The results of the analysis, which design principles can be used to evolve an organizational structure of a factory regarding their changeability will be presented in this paper.

Keywords: Changeability, factory, organization.

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Authors: Abdulmajeed Bashir Mlitan, Ethan Hack

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

Keywords: Pollution, Soil Microbial, Alkomos, Libya.

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Authors: Jongho Park, Jinwoong Choi, Sungnam Hong, Seung-Kyung Kye, Sun-Kyu Park

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Recently, to cope with the rapidly changing construction trend with aging infrastructures, modular bridge technology has been studied actively. Modular bridge is easily constructed by assembling standardized precast structure members in the field. It will be possible to construct rapidly and reduce construction cost efficiently. However, the shape of the transverse connection of T-type girder newly developed between the segmented modules is not verified. Therefore, the verification of the connection shape is needed. In this study, shape of the modular T-girder bridge transverse connection was analyzed by finite element model that was verified in study which was verified model of transverse connection using Abaqus. Connection angle was chosen as the parameter. The result of analyses showed that optimal value of angle is 130 degree.

Keywords: Modular bridge, optimal transverse shape, parameter, FEM.

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Authors: Ahmad M. Abdel Fattah, Ayman M. Bahaa El-Din, Hossam M.A. Fahmy

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Modular multiplication is the basic operation in most public key cryptosystems, such as RSA, DSA, ECC, and DH key exchange. Unfortunately, very large operands (in order of 1024 or 2048 bits) must be used to provide sufficient security strength. The use of such big numbers dramatically slows down the whole cipher system, especially when running on embedded processors. So far, customized hardware accelerators - developed on FPGAs or ASICs - were the best choice for accelerating modular multiplication in embedded environments. On the other hand, many algorithms have been developed to speed up such operations. Examples are the Montgomery modular multiplication and the interleaved modular multiplication algorithms. Combining both customized hardware with an efficient algorithm is expected to provide a much faster cipher system. This paper introduces an enhanced architecture for computing the modular multiplication of two large numbers X and Y modulo a given modulus M. The proposed design is compared with three previous architectures depending on carry save adders and look up tables. Look up tables should be loaded with a set of pre-computed values. Our proposed architecture uses the same carry save addition, but replaces both look up tables and pre-computations with an enhanced version of sign detection techniques. The proposed architecture supports higher frequencies than other architectures. It also has a better overall absolute time for a single operation.

Keywords: Montgomery multiplication, modular multiplication, efficient architecture, FPGA, RSA

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Authors: Khaled Elbehiery, Hussam Elbehiery

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Smart cities are a framework of technologies along with sustainable infrastructure to provide their citizens an improved quality of life, safer environment, affordability, and more, which in turn helps with the society's economic growth. The proposed research will focus on the primary building block of the smart city; the infrastructure of the house itself. The traditional method of building houses has been, for a long time, nothing but a costly manufacturing process, and consequently, buying a house becomes not an option for everyone anymore. The smart cities' Modular Houses are not using traditional building construction materials; the design reduces the common lengthy construction times and associated high costs. The Modular Houses are technological homes, low-cost and customizable based on a family's requirements. In addition, the Modular Houses are environmentally friendly and healthy enough to assist with the pandemic situation.

Keywords: Smart cities, modular houses, single-unit property, multi-unit property, mobility features, chain-supply, livable environment, carbon footprint.

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Authors: Arvind Bhardwaj, Ajay Gupta, Arun Kanda

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Theory of Constraints has been emerging as an important tool for optimization of manufacturing/service systems. Goldratt in his first book “ The Goal " gave the introduction on Theory of Constraints and its applications in a factory scenario. A large number of production managers around the globe read this book but only a few could implement it in their plants because the book did not explain the steps to implement TOC in the factory. To overcome these limitations, Goldratt wrote this book to explain TOC, DBR and the method to implement it. In this paper, an attempt has been made to summarize the salient features of TOC and DBR listed in the book and the correct approach to implement TOC in a factory setting. The simulator available along with the book was actually used by the authors and the claim of Goldratt regarding the use of DBR and Buffer management to ease the work of production managers was tested and was found to be correct.

Keywords: Drum Buffer Rope (DBR), Optimized ProductionTechnology (OPT), Capacity Constrained Resource (CCR)

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Authors: C. Copilusi, C. Ploscaru

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This paper addresses attention to a research regarding the design of a knee orthosis in a modular form used on children walking rehabilitation. This research is focused on the human lower limb kinematic analysis which will be used as input data on virtual simulations and prototype validation. From this analysis, important data will be obtained and used as input for virtual simulations of the knee modular orthosis. Thus, a knee orthosis concept was obtained and validated through virtual simulations by using MSC Adams software. Based on the obtained results, the modular orthosis prototype will be manufactured and presented in this article.

Keywords: Human lower limb, children orthoses, kinematic analysis, knee orthosis.

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Authors: Michael Ajide Oyinloye

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

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

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Authors: S. Ariffin, K. Hasnan, R.H. Weston

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A new generation of manufacturing machines so-called MIMCA (modular and integrated machine control architecture) capable of handling much increased complexity in manufacturing control-systems is presented. Requirement for more flexible and effective control systems for manufacturing machine systems is investigated and dimensioned-which highlights a need for improved means of coordinating and monitoring production machinery and equipment used to- transport material. The MIMCA supports simulation based on machine modeling, was conceived by the authors to address the issues. Essentially MIMCA comprises an organized unification of selected architectural frameworks and modeling methods, which include: NISTRCS, UMC and Colored Timed Petri nets (CTPN). The unification has been achieved; to support the design and construction of hierarchical and distributed machine control which realized the concurrent operation of reusable and distributed machine control components; ability to handle growing complexity; and support requirements for real- time control systems. Thus MIMCA enables mapping between 'what a machine should do' and 'how the machine does it' in a well-defined but flexible way designed to facilitate reconfiguration of machine systems.

Keywords: Machine control, architectures, Petri nets, modularity, modeling, simulation.

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Authors: Onder Yakut, Serdar Solak, Emine Dogru Bolat

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Measuring the Electrocardiogram (ECG) signal is an essential process for the diagnosis of the heart diseases. The ECG signal has the information of the degree of how much the heart performs its functions. In medical diagnosis and treatment systems, Decision Support Systems processing the ECG signal are being developed for the use of clinicians while medical examination. In this study, a modular wireless ECG (WECG) measuring and recording system using a single board computer and e-Health sensor platform is developed. In this designed modular system, after the ECG signal is taken from the body surface by the electrodes first, it is filtered and converted to digital form. Then, it is recorded to the health database using Wi-Fi communication technology. The real time access of the ECG data is provided through the internet utilizing the developed web interface.

Keywords: ECG, e-health sensor shield, raspberry Pi, wifi technology.

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Authors: Uday Hameed Farhan, Majid Tolouei-Rad, Simona O'Brien

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Modular fixtures (MFs) are very important tools in manufacturing processes in terms of reduction the cost and the production time. This paper introduces an automated approach for assembling MFs elements by employing SolidWorks as a powerful 3D CAD software. Visual Basic (VB) programming language was applied integrating with SolidWorks API (Application programming interface) functions. This integration allowed creating plug-in file and generating new menus in the SolidWorks environment. The menus allow the user to select, insert, and assemble MFs elements.

Keywords: Assembly automation, modular fixtures, SolidWorks, Visual Basic.

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Authors: T. Mersmann, P. Nyhuis

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

Keywords: Factory Planning, Stakeholder, Systematization, Sustainability.

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Authors: Phayong Thepaksorn

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

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

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Authors: AHM Shamsuzzoha, Tauno Kekäle, Petri Helo

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Product customization is an essential requirement for manufacturing firms to achieve higher customers- satisfaction and fulfill business target. In order to achieve these objectives, firms need to handle both external varieties such as customer preference, government regulations, cultural considerations etc and internal varieties such as functional requirements of product, production efficiency, quality etc. Both of the varieties need to be accumulated and integrated together for the purpose of producing customized product. These varieties are presented and discussed in this paper along with the perspectives of modular product design and development process. Other development strategies such as modularity, component commonality, product family design and product platform are presented with a view to achieve product variety quickly and economically. A case example both for the concept of modular design and platform based product development process is also presented with the help of design structure matrix (DSM) tool. This paper is concluded with several managerial implications and future research direction.

Keywords: Customization modular design, platform development, product variety.

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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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