Search results for: sinter production

Authors: Uzu-Kuei Hsu, Chang-Hsien Tai, Kai-Wun Jin

Abstract:

When sinters are filled into the cooler from the sintering machine, and the non-uniform distribution of the sinters leads to uneven cooling. This causes the temperature difference of the sinters leaving the cooler to be so large that it results in the conveyors being deformed by the heat. The present work applies CFD method to investigate the thermo flowfield phenomena in a sinter cooler by the Porous Media Model. Using the obtained experimental data to simulate porosity (Ε), permeability (κ), inertial coefficient (F), specific heat (Cp) and effective thermal conductivity (keff) of the sinter packed beds. The physical model is a similar geometry whose Darcy numbers (Da) are similar to the sinter cooler. Using the Cooling Index (CI) and Uniformity Index (UI) to analyze the thermo flowfield in the sinter packed bed obtains the cooling performance of the sinter cooler.

Keywords: Porous media, sinter, cooling index, uniformity index, CFD.

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Authors: Sergei Yendiyarov, Sergei Petrushenko

Abstract:

In this article we present a change point detection algorithm based on the continuous wavelet transform. At the beginning of the article we describe a necessary transformation of a signal which has to be made for the purpose of change detection. Then case study related to iron ore sinter production which can be solved using our proposed technique is discussed. After that we describe a probabilistic algorithm which can be used to find changes using our transformed signal. It is shown that our algorithm works well with the presence of some noise and abnormal random bursts.

Keywords: Change detection, sinter production, wavelet transform.

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Authors: S. Jursová, P. Pustějovská, S. Brožová, J. Bilík

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The paper deals with possibilities of interpretation of iron ore reducibility tests. It presents a mathematical model developed at Centre ENET, VŠB – Technical University of Ostrava, Czech Republic for an evaluation of metallurgical material of blast furnace feedstock such as iron ore, sinter or pellets. According to the data from the test, the model predicts its usage in blast furnace technology and its effects on production parameters of shaft aggregate. At the beginning, the paper sums up the general concept and experience in mathematical modelling of iron ore reduction. It presents basic equation for the calculation and the main parts of the developed model. In the experimental part, there is an example of usage of the mathematical model. The paper describes the usage of data for some predictive calculation. There are presented material, method of carried test of iron ore reducibility. Then there are graphically interpreted effects of used material on carbon consumption, rate of direct reduction and the whole reduction process.

Keywords: Blast furnace technology, iron ore reduction, mathematical model, prediction of iron ore reduction.

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Authors: Yendiyarov Sergei, Zobnin Boris, Petrushenko Sergei

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Usually, the solid-fuel flow of an iron ore sinter plant consists of different types of the solid-fuels, which differ from each other. Information about the composition of the solid-fuel flow usually comes every 8-24 hours. It can be clearly seen that this information cannot be used to control the sintering process in real time. Due to this, we propose an expert system which uses indirect measurements from the process in order to obtain the composition of the solid-fuel flow by solving an optimization task. Then this information can be used to control the sintering process. The proposed technique can be successfully used to improve sinter quality and reduce the amount of solid-fuel used by the process.

Keywords: sintering process, particle swarm optimization, optimal control, expert system, solid-fuel

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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: 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

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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: 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

Abstract:

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

Abstract:

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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Authors: K. Knüppel, G. Meyer, P. Nyhuis

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The increasing interconnectedness and complexity of  production processes raise the susceptibility of production systems to  failure. Therefore, the ability to respond quickly to failures is  increasingly becoming a competitive factor. The research project  "Sustainable failure management in manufacturing SMEs" is  developing a methodology to identify failures in the production and  select preventive and reactive measures in order to correct failures  and to establish sustainable failure management systems.

 

Keywords: Failure categorization, failure management, logistic performance, production optimization.

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Authors: Michael Grigutsch, Marco Kennemann, Peter Nyhuis

Abstract:

Due to the recovering global economy, enterprises are increasingly focusing on logistics. Investing in logistic measures for a production generates a large potential for achieving a good starting point within a competitive field. Unlike during the global economic crisis, enterprises are now challenged with investing available capital to maximize profits. In order to be able to create an informed and quantifiably comprehensible basis for a decision, enterprises need an adequate model for logistically and monetarily evaluating measures in production. The Collaborate Research Centre 489 (SFB 489) at the Institute for Production Systems (IFA) developed a Logistic Information System which provides support in making decisions and is designed specifically for the forging industry. The aim of a project that has been applied for is to now transfer this process in order to develop a universal approach to logistically and monetarily evaluate measures in production.

Keywords: Measures in Production, Logistic Operating Curves, Transfer Functions, Production Logistics

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Authors: Baby Joseph, Sankarganesh Palaniyandi

Abstract:

The enzyme alkaline protease production was determined under solid state fermentation using the soil bacteria Serratia marcescens sp7. The maximum production was obtained from wheat bran medium than ground nut shell and chemically defined medium. The physiological fermentation factors such as pH of the medium (pH 8), Temperature (40oC) and incubation time (48 hrs) played a vital role in alkaline protease production in all the above. 100Mm NaCl has given better resolution during elution of the enzymes. The enzyme production was found to be associated with growth of the bacterial culture.

Keywords: Alkaline protease, Wheat bran, Ground nut shell, Serratia marcescens

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Authors: Mehmet Savsar

Abstract:

This paper presents a model for an unreliable production line, which is operated according to demand with constant work-in-process (CONWIP). A simulation model is developed based on the discrete model and several case problems are analyzed using the model. The model is utilized to optimize storage space capacities at intermediate stages and the number of kanbans at the last stage, which is used to trigger the production at the first stage. Furthermore, effects of several line parameters on production rate are analyzed using design of experiments.

Keywords: Production line simulator, Push-pull system, JIT system, Constant WIP, Machine failures.

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Authors: Behrouz Afshar Nadjafi

Abstract:

Extensive research has been devoted to economic production quantity (EPQ) problem. However, no attention has been paid to problems where production period length is constrained. In this paper, we address the problem of deciding the optimal production quantity and the number of minor setups within each cycle, in which, production period length is constrained but a minor setup is possible for pass the constraint. A mathematical model is developed and Iterated Local Search (ILS) is proposed to solve this problem. Finally, solution procedure illustrated with a numerical example and results are analyzed.

Keywords: EPQ, Inventory control, minor setup, ILS.

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Authors: Amir Azizi, Amir Yazid B. Ali, Loh Wei Ping

Abstract:

Throughput is an important measure of performance of production system. Analyzing and modeling of production throughput is complex in today-s dynamic production systems due to uncertainties of production system. The main reasons are that uncertainties are materialized when the production line faces changes in setup time, machinery break down, lead time of manufacturing, and scraps. Besides, demand changes are fluctuating from time to time for each product type. These uncertainties affect the production performance. This paper proposes Bayesian inference for throughput modeling under five production uncertainties. Bayesian model utilized prior distributions related to previous information about the uncertainties where likelihood distributions are associated to the observed data. Gibbs sampling algorithm as the robust procedure of Monte Carlo Markov chain was employed for sampling unknown parameters and estimating the posterior mean of uncertainties. The Bayesian model was validated with respect to convergence and efficiency of its outputs. The results presented that the proposed Bayesian models were capable to predict the production throughput with accuracy of 98.3%.

Keywords: Bayesian inference, Uncertainty modeling, Monte Carlo Markov chain, Gibbs sampling, Production throughput

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Authors: Bashir Ahmmad, Kensaku Kanomata, Fumihiko Hirose

Abstract:

The effect of carbon materials on TiO₂ for the photocatalytic hydrogen gas production from water / alcohol mixtures was investigated. Single walled carbon nanotubes (SWNTs), multi walled carbon nanotubes (MWNTs), carbon nanofiber (CNF), fullerene (FLN), graphite (GP), and graphite silica (GS) were used as co-catalysts by directly mixing with TiO₂. Drastic synergy effects were found with increase in the amount of hydrogen gas by a factor of ca. 150 and 100 for SWNTs and GS with TiO₂, respectively. Moreover, the increment factor of hydrogen production reached to 180, when the mixture of SWNTs and TiO₂ were smashed in an agate mortar before photocatalytic reactions. The order of H₂ gas production for these carbon materials was SWNTs > GS >> MWNTs > FLN > CNF > GP. To maximize the hydrogen production from SWNTs/TiO₂, various parameters of experimental condition were changed. Also, a comparison between Pt/TiO₂, SWNTs/TiO₂ and GS/TiO₂ was made for the amount of H₂ gas production. Finally, the recyclability of SWNTs/TiO₂or GS/TiO₂ was tested.

Keywords: Photocatalysis, carbon materials, alcohol reforming, hydrogen production, titanium oxide.

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Authors: F. Ardestani, S.A. Fatemi, B. Yakhchali, M. Hosseyni, G. Najafpour

Abstract:

Mycophenolic acid “MPA" is a secondary metabolite of Penicillium bervicompactum with antibiotic and immunosuppressive properties. In this study, fermentation process was established for production of mycophenolic acid by Penicillium bervicompactum MUCL 19011 in shake flask. The maximum MPA production, product yield and productivity were 1.379 g/L, 18.6 mg/g glucose and 4.9 mg/L.h respectively. Glucose consumption, biomass and MPA production profiles were investigated during fermentation time. It was found that MPA production starts approximately after 180 hours and reaches to a maximum at 280 h. In the next step, the effects of methionine and acetate concentrations on MPA production were evaluated. Maximum MPA production, product yield and productivity (1.763 g/L, 23.8 mg/g glucose and 6.30 mg/L. h respectively) were obtained with using 2.5 g/L methionine in culture medium. Further addition of methionine had not more positive effect on MPA production. Finally, results showed that the addition of acetate to the culture medium had not any observable effect on MPA production.

Keywords: Penicillium bervicompactum, Methionine, Mycophenolic acid, Submerged culture

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Authors: M. H. M. Rusli, A. Jaffar, M. T. Ali, S. Muhamud @ Kayat

Abstract:

Lean manufacturing is a production philosophy made popular by Toyota Motor Corporation (TMC). It is globally known as the Toyota Production System (TPS) and has the ultimate aim of reducing cost by thoroughly eliminating wastes or muda. TPS embraces the Just-in-time (JIT) manufacturing; achieving cost reduction through lead time reduction. JIT manufacturing can be achieved by implementing Pull system in the production. Furthermore, TPS aims to improve productivity and creating continuous flow in the production by arranging the machines and processes in cellular configurations. This is called as Cellular Manufacturing Systems (CMS). This paper studies on integrating the CMS with the Pull system to establish a Big Island-Pull system production for High Mix Low Volume (HMLV) products in an automotive component industry. The paper will use the build-in JIT system steps adapted from TMC to create the Pull system production and also create a shojinka line which, according to takt time, has the flexibility to adapt to demand changes simply by adding and taking out manpower. This will lead to optimization in production.

Keywords: Big Island layout, Lean manufacturing, Material and Information Flow Chart, Pull system production, TPS.

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