Integrated Manufacturing Systems Research Articles

An exploration of the integrative function of dialogue in manufacturing

This paper is about the roles of dialogue as a generative mechanism in manufacturing system integration. It advocates the integrative power of dialogue in the design and operation of manufacturing systems. Dialogical conversation is a powerful tool to create a learning organisation: it might be a valuable instrument to implement in manufacturing companies that want to renew themselves, in order to help find assumptions behind the thinking, to discover hidden patterns that block effective behaviours in all sorts of work contexts, and to develop openness, responsibility, and trust in both individual employees and work teams. This paper re-analyses five studies about the introduction of dialogue as a new mode of communication among managers, engineers, and workers in a Dutch manufacturing company. It explores the integrative functions, action and learning triggers, and collective learning processes that dialogue had in this particular case.

Semiotics-based manufacturing systems integration in the advent of a single electronic market

Social and organisational semiotics seek to understand organisations based on the use of signs, documents and communication, and how information can be best used in the scope of organised activities and business domains. This theoretical approach was the ground for a study conducted by a European Commission project envisioning the single integrated information space, where MIS is focal working towards a seamless intra/internet-based structured space for dynamic and value-adding collaboration purposes. Characterised by the semiotics perspective, this paper evaluates at technological level the ATHENA framework for systems interoperability, complemented by non-Technological Interoperability Metrics (nT-IM). Then, based on such results it analyses the vision of stakeholders and concludes with considerations on MSI in the advent of the single electronic market, discussing the correlation of the technical framework and non-technical interoperability measurement indicators with semiotic levels and theories for MIS, identifying the principal challenges for MSI when characterised by the semiotic levels according to the stakeholders recognised issues, as a wider framework for managing integrated complex information systems.

A hybrid particle swarm optimisation algorithm and fuzzy logic for process planning and production scheduling integration in holonic manufacturing systems

Modern manufacturing systems have to cope with dynamic changes and uncertainties such as machine breakdown, hot orders and other kinds of disturbances. Holonic manufacturing systems (HMS) provide a flexible and decentralised manufacturing environment to accommodate changes dynamically. HMS is based on the notion of holon, an autonomous, co-operative and intelligent entity which is able to collaborate with other holons to complete the tasks. HMS requires a robust coordination and collaboration mechanism to allocate available resources to achieve the production goals. In this paper, a basic integrated process planning and scheduling system, which is applicable to the holonic manufacturing systems is presented. A basic architecture of holonic manufacturing system is proposed from the viewpoint of the process planning and the scheduling systems. Here, the process planning is defined as a process to select suitable machining sequences of machining features and suitable operation sequences of machining equipments, taking into consideration the short-term and long-term capacities of machining equipments. A fuzzy inference system (FIS), in choosing alternative machines for integrated process planning and scheduling of a job shop in HMS, is presented. Instead of choosing alternative machines randomly, machines are being selected based on the machine's capacity. The mean time for failure (MTF) values are input in a fuzzy inference mechanism, which outputs the machine reliability. The machine is then being penalised based on the fuzzy output. The most reliable machine will have the higher priority to be chosen. In order to overcome the problem of un-utilisation machines, sometimes faced by unreliable machine, the hybrid particle swarm optimisation (PSO) with differential evolution (DE) has been applied to balance the load for all the machines. Simulation studies show that the proposed system can be used as an effective way of choosing machines in integrated process planning and scheduling.

The Crisis in the U.S. and the Future of East Asian Production Sharing

The East Asian economic zone is well known for its highly integrated manufacturing system that was initialized and is driven by the market mechanism. As participants in a common production sharing network, East Asian economies are highly interdependent. Externally, advanced economies in the West make up the main target markets for exports from East Asia. Moreover, they provide capital to feed the investments required by regional growth. This paper investigates the potential effects of the recent economic crisis on East Asian production sharing. It suggests that the high interdependency of the global economy has made it unlikely for East Asia to remain immune to the crisis. Indeed, the impacts of the crisis on the regional economy in the long run are likely to be more serious than those in the short term. The crisis could be a factor in accelerating the process of East Asian regional integration, especially in terms of financial integration. Fundamentally, the weakness of the East Asian economy comes from its rather passive position in the global industry value chains. In order to improve its core competitiveness in the global market, East Asia needs to increase the technical and knowledge based contents of production sharing. Meanwhile, East Asian countries need to develop a mature social security system to buffer temporary unemployment. By boosting the intra-regional market and strengthening inter-regional cooperation with other emerging economies, East Asia could gradually turn the current production sharing network into a multi-oriented one, allowing the regional economy to be relatively less dependent on the West, and therefore less vulnerable to a crisis originating in the West. Last but not least, it is in the region’s best interests to support the multilateral trade negotiation system in order to secure free trade and capital movement globally.

Designing integrated cellular manufacturing systems with scheduling considering stochastic processing time

This paper addresses a new mathematical model for cellular manufacturing problem integrated with group scheduling in an uncertain space. This model optimizes cell formation and scheduling decisions, concurrently. It is assumed that processing time of parts on machines is stochastic and described by discrete scenarios enhances application of real assumptions in analytical process. This model aims to minimize total expected cost consisting maximum tardiness cost among all parts, cost of subcontracting for exceptional elements and the cost of resource underutilization. Scheduling problem in a cellular manufacturing environment is treated as group scheduling problem, which assumes that all parts in a part family are processed in the same cell and no inter-cellular transfer is needed. Finally, the nonlinear model will be transformed to a linear form in order to solve it for optimality. To solve such a stochastic model, an efficient hybrid method based on new combination of genetic algorithm (GA), simulated annealing (SA) algorithm, and an optimization rule will be proposed where SA and optimization rule are subordinate parts of GA under a self-learning rule criterion. Also, performance and robustness of the algorithm will be verified through some test problems against branch and bound and a heuristic procedure.

Design of integrated manufacturing system of coal preparation plant basedon multi-agent

Production process of coal preparation plant is a complicated process of multi-layer, which is determined by the production characteristics. The emphasis of information construction in coal preparation plant is the automatic data collection and data analysis. This paper constructs the integrated manufacturing system of coal preparation plant based on multi-agent, including the system analysis, module division, module construction, Agent construction, and software implementation. The production automation system has been successfully integrated with the information management, providing a useful auxiliary decision support to the production management in practice.

Manufacturing lot-sizing, procurement and delivery schedules over a finite planning horizon

In this study, an integrated manufacturing system for technology-related companies whose products are experiencing continuous price decrease during the life cycle is studied for optimal procurement, production and delivery schedules over a finite planning horizon. The model considers the inventory cost both at manufacturing and at delivery from supplier. Since the price is continuously decreasing, a manufacturing firm delivers the finished goods in small quantities frequently. Frequent deliveries in small lots are effective to reduce the total cost of the supply chain. The key for high-tech industries is to reduce the inventory holding time since the component prices are continuously decreasing, and this can only be achieved by implementing an efficient supply chain. Therefore, the main purpose of this paper is to develop an integrated inventory model for high-tech industries in JIT environment under continuous price decrease over finite planning horizon while effectively and successfully accomplishing supply chain integration so that the total cost of the system is minimal. An efficient algorithm is developed to determine the optimal or near-optimal lot sizes for raw material procurement, and manufacturing batch under a finite planning horizon. Finally, the solution technique developed for the model is illustrated with numerical examples.

A general framework of a Reference Model for Intelligent Integrated Manufacturing Systems (REMIMS)

Today's highly competitive business environment forces the managers to continuously make the best decisions in the shortest possible time. The ability to provide concurrency among manufacturing functions is a critical need for modern organizations as, especially, distributed environment requires synchronization of manufacturing functions. Moreover, manufacturing companies need to have strong capability of adaptation (agility) mainly because of the dynamic relationships that must be established between manufacturing units. To achieve these, there is a need for an integrated manufacturing system that will handle all interactions and interrelationships which will then be affected by the changes and create maximum gain under limited resources. In order to create and effectively manage such an integrated manufacturing system there is a need for a reference model . In this paper, such a reference model called REference Model for intelligent Integrated Manufacturing System (REMIMS) is introduced. REMIMS has hierarchical architecture with several agents responsible for different manufacturing functions. To facilitate REMIMS and allow interaction among the agents to share their knowledge, a specific knowledge exchange protocol in a knowledge network is being developed.

S1402-1-4 標準技術の相互活用による工場内情報連携(第4報) : MESX-ORiNゲートウェイ(生産システムの新展開(応用・実践1))

Many application systems such as BOM, production schedulers, MES and controllers in the market are available today. However, these application systems depend on vendors. Then integration of whole manufacturing system by integrating with these application systems is difficult and expensive. Meanwhile, IEC 62264-1 had been published for reference architecture for a guide line of integration of manufacturing systems. Therefore, an integration method among application systems on the market using XML technologies for level 2, 3, and 4 of IEC 62264-1 has been proposed from MESX joint project. Moreover, ORiN as a standard technology in the level 2 of IEC 62264-1 has been developed by ORiN forum. In this research, MESX-ORiN Gateway System which can integrate between the level 3 as MES information and level 2 as device information has been developed. This paper describes a concept of the MESX-ORiN Gateway System and development of a demonstration system using the system.

S1402-1-2 標準技術の相互活用による工場内情報連携(第2報) : MESXによる製販一体化2層3層(生産システムの新展開(応用・実践1))

Many software products such as BOM, production schedulers, MES and controllers in the market are available today. However, these products depend on some specific industries or software vendors. Integration of whole manufacturing system by integrating with these products is difficult and expensive. Meanwhile, IEC 62264-1 had been published as a referencing architecture for a guide line of integration of manufacturing systems. Therefore, a method of integration among software products on the market using XML technologies based on the IEC 62264-1 proposed from MESX joint project. Moreover, a coordination protocol among these products positioned on each level of the function hierarchy defined in the IEC 62264-1. A demonstration systems based on the research have been developed. This paper proposes the method for integrating between level 2 and level 3 in the IEC 62264-1, and reports the developed coordination protocol and the demonstration system.

Evolutionary techniques for optimization problems in integrated manufacturing system: State-of-the-art-survey

Integrated manufacturing system (IMS) is a novel manufacturing environment which has been developed for the next generation of manufacturing and processing technologies. It consists of engineering design, process planning, manufacturing, quality management, and storage and retrieval functions. Improving the decision quality in those fields give rise to complex combinatorial optimization problems, unfortunately, most of them fall into the class of NP-hard problems. Find a satisfactory solution in an acceptable time play important roles. Evolutionary techniques (ET) have turned out to be potent methods to solve such kind of optimization problems. How to adapt evolutionary technique to the IMS is very challenging but frustrating. Many efforts have been made in order to give an efficient implementation of ET to optimize the specific problems in IMS. In this paper, we address four crucial issues in IMS, including design, planning, manufacturing, and distribution. Furthermore, some hot topics in these issues are selected to demonstrate the efficiency of ET’s application, such as layout design (LD) problem, flexible job-shop scheduling problem (fJSP), multistage process planning (MPP) problem, and advanced planning and scheduling (APS) problem. First, we formulate a generalized mathematic models for all those problems; several evolutionary algorithms which adapt to the problems have been proposed; some test instances based on the practical problems demonstrate the effectiveness and efficiency of our proposed approach.

Using a system-diagnostic approach to solve information and operation issues in shop-floor integration systems

In order to improve the operation performances of enterprises, managers generally introduce relevant information systems to management, but as the production and operating procedures of enterprises differ, so the composition of the necessary system will also be different. Most research discusses system models and modules in a computer integrated manufacture system (CIMS), but less likely to discuss the problem and settlement method to actually implement. This research focuses on the shop-floor integration system (SFIS) as a real time management system using neural network technology to do the system diagnosis against system operational errors. Furthermore, the approach will discuss and improve the system efficiency by analyzing the questionable information detected. A real case is provided to demonstrate the effectiveness of the presented approach.

Service-oriented communication architecture for automated manufacturing system integration

The heterogeneity of industrial environments is one of the most important challenges in the context of automated manufacturing system integration. To realize common industrial messaging services, this study employs service-oriented philosophy to realize manufacturing message specification (MMS) services and proposes a new concept of MMS Web Services, which rediscovers the semantics of MMS. Then, this study presents manufacturing communication model based on MMS and Web Services and provides service-oriented communication architecture (SOCA). On the basis of describing MMS, a protocol data unit (PDU) design based on Web Services and VMD server message transmission interfaces, manufacturing communication subsystem using unified modeling language model is discussed in detail. In particular, to verify the validity of the proposed design method, a prototype system has been achieved. The resulting prototype proves the effectiveness of MMS standard, Web Services middleware and service-oriented concepts in the design of manufacturing communication architecture. The combination of MMS and Web Services can bring truly platform-independent and language-independent communication capability for automated manufacturing system and improve its flexibility, reconfigurability and interoperability. Furthermore, the proposed communication architecture can be seamlessly integrated into manufacturing control systems or management systems in plug-and-play fashion.

Editorial to 1st International & 22nd AIMTDR

This special issue of IJAMT consists of some select papers of the 1st International and 22nd All India Manufacturing Technology Design and Research (AIMTDR) conference held at Indian Institute of Technology (I.I.T.) Roorkee (India) during Dec.21–23, 2007. Let me give a very brief history of these AIMTDR conferences. The first AIMTDR conference was held at Jadavpur University, Calcutta in the year 1967. Initially, this conference used to be held every year till 1970 but later on the National Advisory committee (NAC) of AIMTDR decided to hold it every alternate year. The first biennial conference was held at University of Roorkee (now, I.I.T. Roorkee) in 1971. Initially, the acronym AIMTDR stood for “All India Machine Tool Design and Research” which was some time in the late 1980s changed to “All India Manufacturing Technology Design and Research” retaining the same AIMTDR acronym. With increasing participation from abroad and to further encourage this trend, a new dimension to the AIMTDR Conference has been added in its latest venture and it has been designated as the 1st International & 22nd AIMTDR Conference. This new name made it possible to include research activities in this conference related to various manufacturing technologies such as casting, forging, machining, inspection, metrology, etc. Not only this, the conference organizers started encouraging research activities related to the newly evolving areas in manufacturing systems and technologies, namely, Computer Integrated Manufacturing Systems, Flexible Manufacturing Systems, Cellular Manufacturing, Just-In-Time, Concurrent Engineering, and so on. In the past one decade or so, many new areas have rapidly emerged especially under the umbrella of nano-technology including μand nano-fabrication, μto nano-finishing, micromachining, μ-forming, μ-forging, and similar other technologies. Computational Manufacturing Engineering (CME) too has been an area of research interest of many researchers since long time. AIMTDR conference also includes research papers related to modeling and simulation of manufacturing processes. Some of the very new areas that are being covered by the AIMTDR conference include Web Manufacturing, Supply Chain Management, Green Manufacturing, Intelligent Manufacturing Systems, and similar others. Manufacturing has been benefited significantly from the recent developments in the areas such as IT, microelectronics, new materials, advanced sensors, and actuators. Computer support in manufacturing covering design, process control, and data transfer has enabled manufacturing to scale new heights leading to globalization and resource optimization. An increased awareness of the environment and the need to conserve energy has led to new developments in this field. International competition with customer focus has brought out the importance of excellence in quality, agility, and cost factors in manufacturing. Environmentally sustainable manufacturing technologies, increased customer expectations, and rapid response to customers need call for constant technological innovations in manufacturing. AIMTDR conferences have been covering many such areas for discussion and publication of research papers thus making it a dynamic conference changing with time to capture the needs of the user industries. This feature of the conference was well reflected in the contributed papers submitted for presentation in the 1st International and 22nd AIMTDR Conference held at Int J Adv Manuf Technol (2008) 38:489–490 DOI 10.1007/s00170-008-1590-6

4th Wave of Modernization by Photon/Electron Technology and Development of Advanced Laser Integrated Manufacturing System (ALIMS)

High power lasers, including CO2 laser, Nd:YAG laser, Excimer laser, Diode laser, LD pumped YAG laser, LD pumped Disk laser, LD pumped Fiber laser and Femto second laser, are now used as a modern tool for industries as well as a computer alike in the 4th wave of modernization. Lasers are currently used for welding, cutting, drilling, cladding, direct fabrication, marking, cleaning, micro-machining peening and forming of materials in modernized factories. The joining speed (= product of welding speed and penetration depth) of 45,000mm2/min for steel sheet can be obtained by a 10kW Yb: fiber laser and is that of 50kW electron beam welding, which require the vacuum chamber. As a result of large numbers of research and developments the Advanced Laser Integrated Manufacturing System (ALIMS) using high power diode lasers has been developed and used for modernization in many industrialized countries. The laser materials processing is now penetrated as a machining tool into many industries. In the present paper, an advanced laser integrated manufacturing systems and its applications to industries such as automotive, electronics, ship building and steel making industry are introduced. In addition, development of an advanced laser integrated manufacturing system using a 2kW fiber laser for welding a car panel and “Laser Roll Welding” system for dissimilar metal joints such as mild steel/high strength steel to aluminium alloys, titanium to aluminium and steel to titanium, is described for modernization of industries. It will be a magnificent for the industries. And the 4th wave of modernization and opto-mechatronics will be promoted more by laser/photon technology in the future.

A comparison of model transformation tools: Application for Transforming GRAI Extended Actigrams into UML Activity Diagrams

Integration of information and manufacturing systems is one of the great achievements of Enterprise Modelling. However, new factors, such as the fast evolution of Information and Communication Technologies (ICT) or the need to set up alliances among different types of enterprises quickly in order to benefit from market opportunities, are causing new types of problems, like interoperability, to appear in the Enterprise Modelling context. This paper shows how a model-driven approach can be useful to solve interoperability problems using model transformations. In particular, the transformation of GRAI Extended Actigrams into UML Activity Diagrams is explored using three different model transformation tools.

Selection of lean manufacturing systems using the PROMETHEE

PurposeIn recent years, many manufacturing companies are attempting to implement lean manufacturing systems (LMS) as an effective manufacturing strategy to survive in a highly competitive market. Such a process of selecting a suitable manufacturing system is highly complex and strategic in nature. The paper aims to how companies make a strategic decision of selecting LMS as part of their manufacturing strategy, and on what basis such strategic decisions are made by the managers.Design/methodology/approachA case study of a small‐ and medium‐sized enterprise is presented, in which the managers are contemplating on implementing either computer integrated manufacturing systems (CIMS) or LMS. To supplement the decision‐making process, a multi‐criteria decision making (MCDM) model, namely, the preference ranking organisation method for enrichment evaluations (PROMETHEE) is used to analyse how it will impact the stakeholders of the organisation, and the benefits gained.FindingsAn extensive analysis of PROMETHEE model revealed that LMS was the best for the given circumstances of the case.Research limitations/implicationsThe same problem can be extended by incorporating the constraints (such as financial, technical, social) of the organisation by utilising an extended version of PROMETHEE called the PROMETHEE V. Since, a single case study approach has been utilised, the findings cannot be generalized for any other industry.Practical limitations/implicationsThe methodology of PROMETHEE and its algorithm has been demonstrated in a detailed way and it is believed that it will be useful for managers to apply such MCDM tools to supplement their decision‐making efforts.Originality/valueAccording to the authors’ knowledge there is no paper in the literature, which discusses the application of PROMETHEE in making a strategic decision of implementing LMS as a part of an organisation's manufacturing strategy.

Integrating manufacturing systems through knowledge exchange protocols within an agent-based Knowledge Network

Manufacturing enterprises need the ability to respond to rapid changes in the market more than ever before. Besides, they are forced to constantly modify their culture and internal organization structures because of change and intense competition in the market. This obviously requires industrial organizations to manage the different components of their organizations by integrating and coordinating them into a highly efficient, effective, and responsive system in order to maintain and improve their competitiveness. This paper presents a knowledge exchange procedure for creating an integrated intelligent manufacturing system. The basic features of the proposed scheme are introduced and the approach is supported through a case study.

712 統合生産システム(IMS)におけるリスク低減戦略の基礎的考察(材料強度と構造設計,オーガナイズドセッション)

This paper shows a new risk reduction strategy for integrated manufacturing systems (IMS). In this strategy, the designer identifies 4 kinds of typical hazardous events of IMS, decides zoning areas of man and machine cooperative working systems, and designs safety control system by using modules that the safety was proven. In this process, safety requirements can be clarified only by writing 4 kinds of new design sheets. The new concept of risk management division and protective measures division are suggested for that purpose.

Uma abordagem metodológica para o desenvolvimento de sistemas automatizados e integrados de manufatura

Este trabalho apresenta uma metodologia de projeto aplicada a sistemas automatizados e integrados de manufatura. A metodologia consiste em um desenvolvimento cíclico de três etapas - modelagem, síntese e implementação - até o atendimento da aplicação demandada para o sistema real, resultando no projeto do sistema automatizado integrado. Esta forma de desenvolvimento permite uma revisão contínua dos resultados obtidos em cada etapa. Para testar e validar a metodologia, é apresentado um exemplo de re-projeto de um protótipo de sistema de manufatura em função da necessidade de inserção de um novo produto.