Abstract
Purpose In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of products. These machines are limited when new product designs are introduced. The solution lies in developing responsive machines that can be adjusted or be changed functionally when these change requirements arise. These machines are reconfigurable machines which are becoming the new focus, as they rapidly respond to product variety and volume changes. A sheet metal working machine known as a reconfigurable guillotine shear and bending press machine (RGS&BPM) has been developed. The purpose of this paper is to present a methodology, function-oriented design approach (FODA), which was developed for the design of the RGS&BPM. Design/methodology/approach The design of the machine is based on the six principles of reconfigurable manufacturing systems (RMSs), namely, modularity, scalability integrability, convertibility, diagnosability and customisability. The methodology seeks to optimise the design process of the RGS&BPM through a design of modules that make up the machine, enable its conversion and reconfiguration. The FODA is focussed on function identification to select the operational function required. Two main functions are recognised for the machine, these being cutting and bending; hence, the design revolves around these two and reconfigurability. Findings The developed design methodology was tested in the design of a prototype for the reconfigurable guillotine shear and bending press machine. The prototype is currently being manufactured and will be subjected to functional tests once completed. This paper is being presented not only to present the methodology by to show and highlight its practical applicability, as the prototype manufacturers have been enthusiastic about this new approach. Research limitations/implications The research was limited to the design methodology for the RGS&BPM, the machine which has been designed to completion using this methodology, with prototype being manufactured. Practical implications This study presents critical steps and considerations in the development of reconfigurable machines. The main thrust being to explore the best possibility of developing the machines with dual functionality that will assist in availing the technology to manufacturer. As the machine has been development, the success of the design can be directly attributed to the FODA methodology, among other contributing factors. It also highlights the significance of the principles of RMS in reconfigurable machine design. Social implications The RGS&BM machine is an answer for the small-to-medium enterprises (SMEs), as the machine replaces two machines with one, and the methodology ensures its affordable design. It contributes immensely to the machine availability by eliminating trial and error approaches. Originality/value This study presents a new approach to the design of reconfigurable dual machines using principles of RMS. As the targeted market is the SME, it is not limited to that as any entrepreneur may use the machine to their advantage. The design methodology presented contributes to the body of knowledge in dual reconfigurable machine tool design.
Highlights
It has been noted in modern production systems that product life cycles are decreasing while the number of product variations keep increasing (Bortolini et al, 2018)
An approach is presented for designing, converting and reconfiguring, in terms of length, the reconfigurable guillotine shear and bending press machine (RGS&BPM)
The current practice is having a guillotine shear and a bending press that are of fixed capacity and when capacity and customer needs change, as is the norm a new investment is required
Summary
It has been noted in modern production systems that product life cycles are decreasing while the number of product variations keep increasing (Bortolini et al, 2018). With such an increase in the frequency of new products, Andersen et al (2015) advocated for a matching manufacturing system, the reconfigurable manufacturing system (RMS) that would rapidly change cost effectively to meet different product demand conditions in terms of variation in volume and characteristics. Sheet metal products find applications in both industrial and consumer goods Products such as motor vehicle bodies, freezers, computers, stoves, trolleys, heavy plant and equipment, hospital equipment, aerospace applications and many more are produced from sheet metal as either frame, housing or other designs
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