Production Control System Research Articles

Study of Protection Mechanism of On Time Delivery with Smart Production Control System in Industry 4.0

In order to achieve on time delivery and win in competition, the Protection Mechanism of On Time Delivery with Smart Production Control System in Industry 4.0 is proposed in this paper from the perspective of process control. The Smart Production Control System is set up for Protection Mechanism with the shortest transmission path and the endogenous security strategy by minimum device cost in Internet of things. The statistical techniques of the Measurement System Analysis, Statistical Process Control and Hypothesis Testing are utilized to analyze the real-time data and monitor business order workflow in the Smart Production Control System. The performance evaluation shows the Protection Mechanism has sufficient capability of Cp>1.33 and Cpk>1 with output increased 51% and days saved 33% for on time delivery, which demonstrates that the Protection Mechanism with Smart Production Control System can ensure on time delivery and achieve business goal in supply chain management in Industry 4.0.

Sustainability of urban aquaponics farms: An emergy point of view

Aquaponics is a food production system that aims higher sustainability by integrating advantages gained from aquaculture and hydroponic production. Aquaponics aims to mimic the biological process that happens in the natural environment in a controlled production system. As it can be applied to small scales, aquaponics is considered an important alternative for urban regions, which have low availability of agricultural land and water resources. Furthermore, the advantage is that it is located close to final consumers. Aquaponics has been labeled as an environmentally friendly food production system, but its demand for energy and materials cast doubt on its sustainability. A systemic understanding of aquaponics production systems is needed to determine the magnitude and balance between its potentialities and constraints, in which emergy synthesis appears as a powerful tool for this purpose. This study applies emergy synthesis to assess the sustainability of two different (scale and marketable products) urban aquaponics farms in Brazil, but differently from other emergy studies, ecosystem services and disservices are included in the analysis as an attempt to represent the system performance holistically. Results show that the type of materials used in aquaponics infrastructures has the highest influence on total emergy demand. Surprisingly, electricity and fish feed showed a low influence on the total emergy, reinforcing the idea that aquaponics systems have a more efficiency feeding management than traditional aquaculture systems. Besides producing vegetables and fish, the inclusion of ecosystem services highlights the importance of aquaponics for educational and tourism purposes. Finally, the obtained indicators from modeling scenarios revealed that replacing the water source and some materials deserves priority attention to increase the sustainability of urban aquaponics farms.

A heijunka study for the production of standard parts included in a customized finished product.

Efficient order execution plays a crucial role in the activity of every company. In production planning it is important to find a balance between the fluctuations of orders and stability of production flow regarding the company. One of the methods of achieving this goal is heijunka (production leveling). This paper presents a study of choosing the best variant of the production planning and control system for the production of standard parts. Three variants are investigated regarding delays in order delivery. The analysis of variants was conducted using a simulation method. The method of choosing the best variant for the production system being investigated is also proposed. The results show that the best variant is a mix of production leveling and production "for stock".

Automated process control system of Jaw crusher production

Rocks go through a series of crushing stages to produce the final aggregate size which suit customer’s needs. Aggregate crushers suffer from many problems in reality that affect its production processes badly and may lead to its stoppage. These problems could be unchangeable feed rate, hidden steel part between rocks and wastage from storing final aggregate stockpile on the ground. The purpose of this research is to develop an automated control system for Jaw crusher production process as a solution for the real specified problems to get more productive aggregate production. First a 3D model which mimic exactly the real crushing plant was built to test the proposed system. Then a C++ code was programmed to control the proposed system components such as motor, sensors and LCD screens. Thereafter, the aggregate flow simulation program (AggFlow) is utilized to simulate the proposed system results. Cost analysis calculations were performed to explore the impact of proposed system on the production process cost and time. Finally, the results confirmed that the proposed system enhance and increase the crusher production process. As it shows increase in the crusher automatic control, the net profit and the feed rate while decrease in the final product waste.

QUALITY MANAGEMENT SYSTEM TO IMPROVE THE QUALITY AND EFFICIENCY OF THE PRODUCTION OF BUTTERMILK WITH MUSHROOMS

In order to obtain safe and high quality dairy products, fermented dairy processors implement and maintain procedures based on HACCP principles, which are based on a systemic approach to risks and corrective measures to eliminate any potential risk associated with food safety. The aim of this study was to use tools to analyze hazard, risk assessment and determine critical control points during the production process of buttermilk with mushrooms as an innovative product. The safety control system for fermented dairy products based on HACCP concepts, involves a systemic approach to risks and corrective measures to eliminate any potential risk associated with food safety.

STUDY OF PHARMACEUTICAL INVENTORY CONTROL SYSTEM IN SEVERAL PHARMACIES IN KARANGASEM, BALI

The control of pharmaceutical products is one of the pharmaceutical services at the Pharmacy that is regulated in Permenkes RI No. 73 of 2016. The pharmacy control of each pharmacy must always apply the principles stated in the Good Pharmacy Practice (GPP) guidelines. GPP is a pharmaceutical practice that responds to the needs of people who use pharmacist services to provide optimal and evidence-based care. This study aims to determine the system of one of the pharmaceutical service standards, namely the control of pharmaceutical products in several pharmacies in Karangasem, Bali. This type of research is observational descriptive. Data retrieval is carried out in a retrospective manner related to the pharmaceutical product control system in the form of an order or procurement, dispensing, and handling system. Most pharmacies are researched to apply the same control system in the procurement and spending of pharmaceutical products. Only the pharmaceutical product system for handling parts has a slight difference in each pharmacy.

Sewage Sludge - a Sustainable Material for the Production of Solid Recovered Fuel

The appropriate quality system of production control of pre-treated sewage sludge and its characterization needs to be established in order to provide confidence in its constant quality as a raw material in the circular economy. Waste to energy procedure with increased energy efficiency in utilization of its residues is gaining an increased recognition. To manage waste to energy procedure the pre-treated (dried) sludge must be continuously assessed in accordance with the CEN/TC 343 technical standards and the European Union (EU) initiative for circular economy. In evaluation of the dried sewage sludge as an alternative solid recovered fuel (SRF), three parameters are important – net calorific value (NCV), chlorine (Cl) and mercury (Hg) content. The statement of the authorized contractor on the quality of sewage sludge as a SRF with the Class code NCV 3 to 4; Cl 1; Hg 3 creates confidence in its stable quality for energy production in cement kilns, power plants and dedicated sludge mono-incinerators. The removal of Hg from municipal wastewater, constant quality control of the dried sewage sludge, and tracking the mass balance of Hg during incineration make it possible to prevent the circulation of this critical pollutant in the environment.

Order release in production planning and control systems: challenges and opportunities

Production planning and control (PPC) systems are important to the competitiveness of manufacturing firms and their ability to benefit from recent technological advances. We give an overview of research and unsolved research questions in PPC systems related to the order release function that sets output targets for autonomous production units that manage production at the shop-floor level. We describe the hierarchical Manufacturing Planning and Control (MPC) and Advanced Planning and Scheduling (APS) architectures for PPC systems prevalent in practice and the positioning of the order release task within these frameworks. We then describe the research streams relevant to order release, optimisation models for order release planning, and the relation of these models to the overall PPC system. Modelling the dynamic response of production units to time-varying work input, which represents an extension of classical production theory by incorporating the time dimension, is identified as the major modelling challenge. We conclude by suggesting several unsolved research questions that should encourage researchers to work on this topic which is far from mature.

Computational methods based on fuzzy control algorithms for operational control and identification of control systems in smart production

The problem of the functioning of complex technical systems is studied in this article. The authors consider the problem of structural and functional redundancy (the complexity of formalizing computational methods for dynamic and nonlinear systems used in modern industrial production). On the example of considering the structure of the climate control subsystem for a closed loop of an industrial unit, a fuzzy configurator model for controlling the operation of a refrigerator is formalized. It is reduced to: linearization of the reading of instantaneous temperatures from various loops of the considered control system, followed by fuzzification and antecedent analysis. Eventually this allows to implement a complex method of fuzzy control and calculation of structural redundancy in any configuration with a different probability ratio. The authors also raise the question of the comparability of the obtained data and application of the developed method as a tool for predictive analytics in technological processes of production management.

Integral Layout Optimization of Subsea Production Control System Considering Three-Dimensional Space Constraint

The subsea production control system, characterized by a complex and diverse structure and high cost, is one of the essential parts of a subsea production system. The rational layout of the subsea production control system is essential to reduce development costs and ensure safe production in offshore fields. Most previous studies on layout design in offshore fields have focused on the oil- and gas-gathering system. However, the layout of the subsea production control system has not thoroughly been researched to date and the seabed terrain and integral optimization have rarely been discussed. This paper focuses on the multi-layer star structure and multi-layer star-tree structure, two common layout structures of subsea production control systems, and establishes the corresponding model with obstacle and seabed terrain conditions. Obtaining the lowest possible total cost was the aim of the model. A hybrid algorithm combining the adaptive mutation particle swarm algorithm and the A-star algorithm was applied to integrally optimize the subsea distribution unit and umbilical touch down point positions, the pipe connection topology and pipe routes. The practicality of this approach is demonstrated by designing a layout with one FPSO and 22 subsea control modules. The results indicate that the multi-layer star-tree layout structure has a lower total cost compared to that of the multi-layer star layout structure. In addition, the results were compared with a case that ignores the seabed terrain, indicating differences in the total construction cost. This method provides engineers with quantitative references and reliable cost estimates to make decisions regarding the layout of the subsea production control system.

Development of a two-level control system for the analysis of the composition of meat products

Because of the increased demand for processed meat, there is an urgent need to introduce specific identification methods. Strategies such as molecular genetics and the physical condition of meat are used to quickly explore multi-component products. However, a single methodology does not always unambiguously classify a product as counterfeit. In laboratory practice, as a rule, screening techniques are rarely used in the first stage, followed by arbitration. This work aimed to study individual methodologies using artificially falsified meat samples as examples and to identify their composition based on muscle tissue. For the experiments, the three most common types of raw meat were selected: pork, beef, and chicken. The calculation of the content of muscle tissue was carried out according to the BEFFE method. The study of muscle protein was carried out by ICA, ELISA, PCR, microstructural analysis, and mass spectrometric identification. In this connection, we proposed a multilevel control system for multicomponent meat products. Both classical methodologies, such as calculation by prescription bookmarks (BEFFE) and microstructural analysis, and approaches of highly sensitive methodologies, such as identification of muscle tissue by marker peptides (LC/MS-MRM) and semi-quantitative PCR analysis, were evaluated.

SOLVING THE ISSUE OF MODERNIZATION OF PRODUCTION EQUIPMENT USING CYBER-PHYSICAL MANUFACTURING CONTROL SYSTEMS

Continuous improvement of the fleet of technological equipment, in the conditions of existing production, is a difficult task, the solution of which must take into account many parameters, such as mechanization, automation and application of new technologies within the concept of Industry 4.0. One of the effective methods of improving the technical and economic indicators and reliability of production is the modernization of existing technological equipment, which is based on the need to use modern methods of development and implementation of information technology, such as Industrial Internet of Things, cyber-physical production systems. The subject of this study is the testing of methods for developing additive cyber design for automation of complex industrial equipment. The goal of this article is to develop a cyber-physical production control system for the modernization of the DA2238B hydraulic press. To achieve this goal it is necessary to solve the following tasks: to analyze the technical characteristics and control system of the hydraulic press DA2238B; to carry out research of the scheme of hydraulic basic and, taking it into account, to choose sensors and executive mechanisms, and also operating modes; to develop the scheme of inclusion of the hydro equipment; to develop an automated control system based on a modern single-board computer and to develop an intuitive additive cyber-design of the operator interface; to conduct experimental research. Conclusions: as a result of research, a block diagram was developed and an automated control system based on LattePanda was implemented. Selected pressure and temperature sensors for control of pressing processes, which allowed to ensure accurate compliance with the requirements of the technological process. An automated operator's workplace has been developed, in which touch control based on additive cyber-design has been implemented. The developed control system provides: collection and analysis of production data on the basis of which it is possible to improve production technology and to provide forecasting of achievement "Lean Manufacturing".

Managing quality control systems in intelligence production and manufacturing in contemporary time

In contemporary time, the production arena has become an interesting scene with introduction of innovations that is changing the climate of production technology. The innovation comes in the form of smart technique of production for an enhanced productivity. Which is termed intelligence manufacturing or production. Intelligence manufacturing has led to enhance productivity in manufacturing sector in recent time on account of 4th industrial revolution. Intelligent manufacturing (IM) involves the use of sophisticated and advanced analytics, sensor application in robotics and internet based connections to things popularly known as IoT. This study was centered on application of intelligent manufacturing in industrial productivity and cost/time wastage. Purposive sampling method was adopted in this study, random sampling survey methods was used to pick samples for collation of responses from production managers of manufacturing companies at the study area (Lagos state, Nigeria). Population frame of 100 product manufacturing companies was adopted, out of which 73 respondents that constitute production managers and supervisors were selected using random sampling technique. The study censored the opinion and view of professionals such as managers (production), production supervisors on calibrated. The study highlighted emerging areas of application of quality monitoring system in intelligent manufacturing to include advanced analytical tools and censored based applications such as robotics applications used in design and product calibration, virtual and augmented reality application that simulates real situation using virtual approach, machine learning, expert systems (AI), block chain technology, drones for real time supervision of production process.

Development of Quality Control Methods for Dispersibility and Stability of Single-Wall Carbon Nanotubes in an Aqueous Medium.

The attractive properties of single-wall carbon nanotubes (SWCNT) such as mechanical strength and high electrical and thermal conductivity are often undercut by their agglomeration and re-agglomeration tendencies. As a result, the application of SWCNT as additives in advanced composite materials remain far from their potential, with proper dispersion being the major inhibitor. This work presents a dispersion quality control approach for water-based SWCNT dispersions (dispersed by a unique combination of physical and chemical methods), using complementary and easily scalable, characterization methods. UV-Vis spectroscopy, rheological measurements, and precipitant sheet resistance were used to understand the properties of the initial solution through processing and application. From an industrial perspective, these methods are fast and easy to measure while giving a repetitive and quick indication of dispersion quality and stability. The methods were correlated with microscopy and Raman spectroscopy to validate dispersion and SWCNT quality under various dispersing energies. The protocol was then applied to estimate the stability of SWCNT solutions, as well as the effectiveness of different surfactants in aiding dispersion. The simple, fast, and scalable combination of different characterizations provides good SWCNT dispersion and can be used as a quality control system for industrial production and usage.

Constructing a smart framework for supplying the biogas energy in green buildings using an integration of response surface methodology, artificial intelligence and petri net modelling

Nowadays, energy crisis is considered an essential active issue for future urbanization in megacities. While the rate of population growth increases, the volume of municipal solid waste production increases significantly. This highlights the need of Sustainable Development Goals (SDGs) for both developed and developing countries. This paper constructs a novel smart framework for supplying biogas energy. Our study is applicable for fields of waste management and energy supply in green buildings. The proposed framework integrates the Response Surface Methodology (RSM), Artificial Intelligence (AI), and Petri net modeling. In this regard, the AI techniques including the Random Tree (RT), Random Forest (RF), Artificial Neural Network (ANN) and, Adaptive-Network-based Fuzzy Inference System (ANFIS) are employed. In addition, for creating the optimum condition, a dynamic control system using the Petri Net modeling is applied. Among all machine learning methods, ANFIS with 0.99 correlation coefficient had the best accuracy for Accumulated Biogas Production (ABP) based on effective factors. Finally, the main findings of this paper are to introduce a novel framework for addressing different scientific issues such as supplying the clean energy in green buildings, the development of a smart and sustainable biogas production control system, integration of solid waste management with the SDGs in green buildings.

Explainable reinforcement learning in production control of job shop manufacturing system

Manufacturing in the age of Industry 4.0 can be characterised by a high product variety and complex material flows. The increasing individualisation of products requires adaptive production planning and control systems. Research in the area of Machine Learning demonstrates the applicability and potential of Reinforcement Learning (RL) systems for the control of complex manufacturing. However, a major disadvantage of RL-methods is that they are usually considered as ‘black box’ models. For this reason, this paper investigates methods of explainable reinforcement learning in production control. Based on a comprehensive literature review an approach to increase the plausibility of RL-based control strategies is presented. The approach combines the advantages of high prediction accuracy (e.g. neural networks) and high explainability (e.g. decision trees). In doing so, understandable control strategies such as heuristics can be generated, and an advanced RL-system can be designed including specific domain expertise. The results are demonstrated based on a real-world system, taken from semiconductor manufacturing, which is investigated in a simulated approach.

Power marketing and distribution network remote visual control system based on big data architecture

As the main power transmission system connecting power supply equipment and power customers, whether the distribution network is safe and reliable in production and operation directly determines whether the work capacity of power supply equipment and power consumption equipment can be improved. The application of big data centralized control system can help us timely and accurately grasp the reasons for the decline of security and reliability of distribution network, and provide safe and stable power energy for power customers while improving the operation efficiency of power supply system. On the basis of previous research results, the author systematically analyzes the role of big data centralized control system in distribution network production and operation management, and puts forward some suggestions on applying big data centralized control system to distribution network production and operation management according to his many years of work experience. The comparative experiment proves that the fault location accuracy of the system designed in this paper is higher than 90%, which effectively increases the fault detection accuracy.

Adaptive Coordinated Control Strategy of Multi Manipulator System based on Multi-Agent

With people's increasing awareness of life and the increasing complexity of exploration in unknown environment, a single robot can not meet the increasing demand, including the price, flexibility and efficiency of robots. As a common mechanical control system in industrial production instead of human production, multi manipulator system can be applied in complex environment, multi task and other conditions. In order to settle the coordinated control fault of multi manipulator system, we study adaptive coordinated control strategy with the help of multi-agent research method in this paper, which can simplify the complexity of the problem and design an efficient and feasible system control protocol. The complex items in the multi manipulator system are treated as non affine systems. Using the design idea of non affine algorithm, combined with implicit function theorem and median theorem, the non affine system is transformed into affine systems, the controller is separated, and a distributed adaptive control strategy is designed. The results indicate that manipulator systems can effectively track the active manipulator system in finite time and the significance of the algorithm is proven by MATLAB simulation analysis.

Perencanaan dan Pengendalian Produksi Dalam Sistem Logistik (Pendekatan Berbasis Praktikum Laboratorium)

The concept of Production Planning and Control is closely related to logistics activities, including in determining the production of a product. Production planning and control aims to get a complete picture of how to plan and control production in the industry of each company, so that all costs can be reduced. Production planning, Rough Cut Capacity Planning (RCCP), Material Requirement Planning (MRP), Capacity Requirement Planning (CRP), and Line Balancing are some of the steps that need to be done in providing an overview of the production planning and control system at the "Tamiya" Company. Production planning results in the amount of "Tamiya" production in a certain period by considering SEE and the most appropriate production strategy that results in total costs. MPS validation considerations are the output of the RCCP calculation, a comparison of the ratio of the required capacity to the capacity of the company. The MRP stage reduces production due to material unavailability, the result is the best material scheduling based on the lot sizing method which provides the lowest cost. CRP generates Planned Input and Planned Output per work station to see the balance between load and capacity. Line Balancing functions to balance assignments through the Ranking Position Weight (RPW) and Presedence Diagram methods, getting results in the form of updating the layout of the assignment so that the efficiency of the production line can be improved

Development and implementation of standardized measurement and control system

At present, due to the variety of product models and the increasing production data, the existing single machine based tester can not meet the needs of production. This paper introduce how to design and develop a centralized measurement and control system for servo products through standardized design and craft configuration.