Production Line System Research Articles

A Novel S-F Seru Production Scheme

S-F scheme is a four dimensions analysis framework of Substance-structure-form-Function, a useful tool to evaluate the behaviors of an organization. In this paper, we first try to define seru production system by using the S-F systematic concept. For example, Substance of seru production system can be recognized as a new system shakes off traditional belt conveyer assembly line. However, because structure shows the combinations of elements in a set and frame of thing, it has a special characteristic of isomorphism to say different substances may have same structure. Therefore it also can be observed that many similarities exist in assembly line, cellular manufacture and seru production system. form of seru production system can be described to response changing market demand quickly, flexibly and effectively. Different form may response different objective, so that seru production systems may have several different forms. Finally, Function is to say what seru production can do. For example, reduce manpower, space, inventory and lead time; increase moral of workers and product quality; quickly response to market and so on. However, because the S-F scheme includes a lot of terms (concepts), what term is which part of S-F scheme should be determined. Then we provide a text mining approach to find the terms from published materials (books, magazines, newspapers and websites), a common clustering analysis is used to determine the positions of terms in a S-F scheme. Finally the novel S-F seru production scheme can make a systematical description of seru production system and give an useful indicator when a seru production system is introduced or an exist seru production system has been evaluated.

Considering Product Life Cycle Stages and Worker Skill Level in Seru Production Systems

The product life cycle (PLC) stages can be considered as introduction, growth, maturity, and decline. Seru production systems has a potential to perform better where products have high demand variability and low volume during the introduction and decline stages. On the other hand, the assembly line is popular in the final processes of mass production systems due to its high efficiency, low product cost owing to economy of scale, and low labor cost by low-skilled workers. Therefore, an assembly line design is more successful for growth and maturity stages of a product where the demand is more stable. Likewise, if skill level of workers for different tasks have higher variation, assembly line can be considered as a better option. Hybrid system of assembly line and seru production system performs better with workers who have less skill variation. A worker is expected to improve his/her skill levels when performing a task continuously leading to seru production system with low skill level variation. Therefore, this study aims to introduce the details of a preliminary approach considering product life cycle stages and worker skill requirements.

Search-Based test case prioritization for simulation-Based testing of cyber-Physical system product lines

Cyber-Physical Systems (CPSs) integrate computation with physical processes. These systems are usually highly configurable to address different customer needs and are evolving to be CPS product lines. The variability of CPS product lines is large, which implies that they can be set into millions of configurations. As a result, different cost-effective methods are needed to optimize the test process of these systems. We propose a search-based approach that aims to cost-effectively optimize the test process of CPS product lines by prioritizing the test cases that are executed in specific products at different test levels. The prioritized test suite aims at reducing the fault detection time, the simulation time and the time required to cover functional and non-functional requirements.We compared our approach by integrating five search algorithms as well as Random Search (RS) using four case studies. As compared with RS, the search algorithms managed to reduce fault detection time by 47%, the simulation time by 23%, the functional requirements covering time by 22% and the non-functional requirements covering time by 47%. Moreover, we observed that the performance of search algorithms varied for different case studies but the local search algorithms were more effective than the global search algorithms.

Robust Self-Calibrated Dynamic Voltage Scaling in FPGAs With Thermal and IR-Drop Compensation

Field programmable gate arrays (FPGAs) are widely used in telecom, medical, military, cloud computing, and other high-performance computing applications, thanks to their unique combination of parallel hardware execution and reprogrammability. During compilation, the computer-aided design (CAD) tool estimates the maximum operating frequency of the user application based on the worst case timing analysis of the critical path at a fixed nominal supply voltage, which usually results in significant voltage or frequency margin. Hence dynamic voltage scaling (DVS) has great potential to reduce the power overhead in FPGAs; however, the reprogrammability of FPGAs make a safe implementation of DVS for any application that could be programmed into the FPGA challenging. This work presents a robust universal DVS scheme for FPGAs intended to run on a system production line, or regularly during each FPGA power-up. The proposed scheme requires the FPGA to be programmed twice: offline self-calibration and online DVS. During the offline self-calibration, the FPGA frequency and core voltage operating limits at different self-imposed temperatures are automatically found and stored in a calibration table (CT). During online operation, the power stage refers to the CT and dynamically adjusts the core voltage according to the FPGA temperature and the resistive voltage drop in the power delivery path. The proposed DVS scheme is demonstrated on a 60-nm Intel Cyclone IV FPGA, with a digitally controlled dc–dc converter, leading to 40% power savings in two typical applications.

Demand response scheduling in industrial asynchronous production lines constrained by available power and production rate

Energy efficiency in factories is a new paradigm arising with Demand Response (DR) programs that enables energy providers to ask their clients to reduce their power consumption for a given time. In this paper, we consider demand side management of an industrial customer who owns asynchronous production line systems. Our aim is to help the customer achieve a good trade-off between production rates and power consumption during DR events. To attain this objective, we develop a framework named DR-Mgmt to schedule activities of machines on production lines so that the number of simultaneously working machines is maximized while satisfying DR constraints. Our framework first models activities of a production line using a new approach based on temporal deterministic finite station machine concept, where each state represents machine status (working/idle) and transitions capture temporal changes. Then, the problem of finding an optimal schedule from all feasible schedules is handled by selecting the optimal set of state transitions. We adapt the well-known local search heuristic to find near-optimal transitions. Numerical results show a significant benefit of our approach on production rates during DR intervals. Compared to other approaches, the proposed framework performs best and improves production rates up to 70% in some cases with higher total power consumption. We also validate our work by a real case study.

Experimental and numerical study of the effects of pre-drying of S-PVC using a pneumatic dryer

ABSTRACT Pneumatic conveying drying (PCD) has been widely used in industrial processes because it is regarded as a highly efficient technique in heating, and mass transfer of product operation. Despite the fact that the use of multi-stage drying techniques is now justifiable, many industrial complexes still use older single-stage systems. The purpose of this article is to investigate the effects of using a pneumatic dryer as a pre-dryer in PVC suspension production line at Bandar Imam Petrochemical Complex (BIPC). The current operating system in PVC suspension production line is fluidized bed drying. In the present work, computational fluid dynamics (CFD) is utilized to predict the hydrodynamics and drying mechanisms of a three-dimensional, dilute-phase, gas-solid turbulent flow in the laboratory-scale. The experimental study is carried out in two pilot-scale spiral pneumatic conveying dryers of diameter 5 cm and 13.45 m length and diameter 10 cm and 7.2 m length. As the main goals of this research, the influence of diameter and length of the dryer are investigated in two pilot-scale vertical pneumatic conveying dryers. In addition, the effects of gas velocity and temperature, particle temperature, mass flow rate and initial moisture content on the dryer performance are examined. The variations in the air velocity, air temperature, air pressure and particle moisture content are investigated along the length of the dryer. The results of energy analysis show that by using the pneumatic dryer as a pre-dryer, the specific energy consumption is reduced about 23.1%.

Synergy: Agile Systems Engineering and Product Line Engineering at Rockwell Collins

ABSTRACTRockwell Collins, in Cedar Rapids, US‐IA, uses a product line approach for a family of radios they produce for military and international markets, and employs an agile systems engineering process that asynchronously aligns software, firmware, and hardware development increments. This mixed‐discipline engineering group encompasses some 350 employees working on multiple projects simultaneously for multiple customers. Key concepts enabling and facilitating agility include a product line architecture, active forward‐looking needs awareness and opportunity management, organizational relationship management, cross‐discipline development increment coupling, and an infrastructure platform for hardware and firmware development.

On the Formulation of the Problem of Optimal Control of Production Parameters using a Two-Level Model of the Production Process

Using a statistical approach, widespread in natural sciences, a two-level model to control the parameters of the flow line production system has been built. The state of the system is given by the amounts of sets of the objects of labour. The state of the subject of labour is given by a point in the phase space. The function of the distribution of objects of labour by the state is introduced and the kinetic equation for the distribution function is written. Now we have closed system of dynamical equations for parameters of flow production line. The null and the first moments of the distribution function of labour objects in terms of the state characterize the magnitude of inter-operational stocks and the rate of processing of labour objects from operations of the technological route and are the main parameters of the management of the production line. The limiting transition from the kinetic description of the state of objects of labour to the stream description of the processing of objects of labour is accomplished. Integration of the kinetic equation by the states of the objects of labour made it possible to construct a closed system of balance equations for the parameters of the production line. The task of optimal control of the flow parameters of the production line has been set. The balance equations for the moments of the distribution function of objects of labour by states determine the constraint equations in the control problem

Empirical Software Engineering, Predictive Models, and Product Lines

This issue’s column reports on presentations at the 11th International Symposium on Empirical Software Engineering and Measurement, 13th International Conference on Predictive Models and Data Analytics in Software Engineering, and 21st International Systems and Software Product Line Conference.

On the Formulation of the Problem of Optimal Control of Production Parameters Using a Two-Level Model of the Production Process

Using a statistical approach, widespread in natural sciences, a two-level model to control the parameters of the flow line production system has been built. The state of the system is given by the amounts of sets of the objects of labour. The state of the subject of labour is given by a point in the phase space. The function of distribution of objects of labour by state is introduced and the kinetic equation for the distribution function is written. Now we have closed system of dynamical equations for parameters of flow production line. The null and the first moments of the distribution function of labor objects in terms of the state characterize the magnitude of interoperational stocks and the rate of processing of labor objects from operations of the technological route and are the main parameters of the management of the production line. The limiting transition from the kinetic description of the state of objects of labor to the stream description of the processing of objects of labor is accomplished. Integration of the kinetic equation by the states of the objects of labor made it possible to construct a closed system of balance equations for the parameters of the production line. The task of optimal control of the flow parameters of the production line has been set. The balance equations for the moments of the distribution function of objects of labor by states determine the constraint equations in the control problem.

Enabling automated requirements reuse and configuration

A system product line (PL) often has a large number of reusable and configurable requirements, which in practice are organized hierarchically based on the architecture of the PL. However, the current literature lacks approaches that can help practitioners to systematically and automatically develop structured and configuration-ready PL requirements repositories. In the context of product line engineering and model-based engineering, automatic requirements structuring can benefit from models. Such a structured PL requirements repository can greatly facilitate the development of product-specific requirements repository, the product configuration at the requirements level, and the smooth transition to downstream product configuration phases (e.g., at the architecture design phase). In this paper, we propose a methodology with tool support, named as Zen-ReqConfig, to tackle the above challenge. Zen-ReqConfig is built on existing model-based technologies, natural language processing, and similarity measure techniques. It automatically devises a hierarchical structure for a PL requirements repository, automatically identifies variabilities in textual requirements, and facilitates the configuration of products at the requirements level, based on two types of variability modeling techniques [i.e., cardinality-based feature modeling (CBFM) and a UML-based variability modeling methodology (named as SimPL)]. We evaluated Zen-ReqConfig with five case studies. Results show that Zen-ReqConfig can achieve a better performance based on the character-based similarity measure Jaro than the term-based similarity measure Jaccard. With Jaro, Zen-ReqConfig can allocate textual requirements with high precision and recall, both over 95% on average and identify variabilities in textual requirements with high precision (over 97% on average) and recall (over 94% on average). Zen-ReqConfig achieved very good time performance: with less than a second for generating a hierarchical structure and less than 2 s on average for allocating a requirement. When comparing SimPL and CBFM, no practically significant difference was observed, and they both performed well when integrated with Zen-ReqConfig.

APLIKASI BINARY INTEGER PROGRAMMING PADA PENYELESAIAN MASALAH LINE BALANCING

The proper assignment of work activities in a number of workstations in a production line system influences heavily the success of the production process. This problem is hitherto solved by trial and error or using the heuristic method which naturally does not ensure an optimal solution. The method of Binary Integer Programming is here proposed to solve this problem, which will ultimately guarantee an optimal solution. Optimization is carried out by formulating mathematical model programming with an objective function compelled to achieve the minimum number of workstations. This optimization is performed under the constraints of interdependency between work activities, cycle time, activities time, demand, and productive time available. The model is then employed in the production of women slipper. Optimization carried out by suitable software is proven able to assign each work activity in a specific workstation with an optimal efficiency. Comparison with the current performance shows a substantial efficiency increase.

Where the big bucks (will) come from – Implementing Product Line Engineering for Railway Rolling Stock

AbstractThis paper presents a “mid‐term” return of experience form ALSTOM Rolling Stock on its implementation of Product Line Engineering (PLE). It describes the journey we have undertaken to implement PLE, the challenges we have had to face and the manner in which we are finding our way (most of the time deliberately, sometimes fortuitously) to define a profitable reuse strategy and to structure our approach on PLE. The paper also presents some encouraging intermediate results and concludes with the perspectives and the future challenges in our search for Product Line Systems Engineering excellence.

An Enterprise Feature Ontology for Feature‐Based Product Line Engineering

AbstractFeature‐Based Software and Systems Product Line Engineering (“Feature‐Based PLE”) has emerged as a modern, repeatable, codified, and proven‐in‐practice specialization of generic PLE practice. Feature‐Based PLE involves automation‐supported configuration of engineering and operations artifacts from across an enterprise, to reflect the feature choices embodied by a product. Configuration of artifacts based on feature choices is a powerful narrative, but what actually constitutes a feature? A feature is a distinguishing characteristic that sets products apart (Kang et al. 1990) but in practice this concept encompasses a broad spectrum of granularity. Stakeholders who are concerned with the finest‐grained differences are very different from those who care about the coarsest‐grained differences. This paper presents an ontology for features that is capable of supporting an entire enterprise of product line engineering and business operations, and shows how various stakeholders throughout the enterprise can interact with these different kinds of features.

Exergetic performance analysis of an ice-cream manufacturing plant: A comprehensive survey

In this study, a comprehensive exergetic performance analysis of an ice-cream manufacturing plant was conducted in order to pinpoint the locations of thermodynamic inefficiencies. Exergetic performance parameters of each subunit of the plant were determined and illustrated individually through writing and solving energy and exergy balance equations on the basis of real operational data. The required data were acquired from a local ice-cream factory located in Tehran, Iran. The plant included three main subsystems including water steam generator, refrigeration system, and ice-cream production line. An attempt was also made to quantify the specific exergy destruction of the ice-cream manufacturing process. The functional exergetic efficiency of the water steam generator, refrigeration system, and ice-cream production line was determined at 17.45%, 25.52%, and 5.71%, respectively. The overall functional exergetic efficiency of the process was found to be 2.15%, while the specific exergy destruction was calculated as 719.80 kJ/kg. In general, exergy analysis and its derivatives could provide invaluable information over the conventional energy analysis, suggesting potential locations for the plant performance improvement.

Applying Composable Architectures to the Design and Development of a Product Line of Complex Systems

This paper investigates a composable design methodology leveraging SysML to manage mission flexible product lines, and reviews the application of this methodology to a spacecraft product line. This methodology extends the SysML language with a mathematical and Boolean constraint language allowing for the capture of product line rules as an alternative to a more traditional variation tree. Finally, this paper reviews future work underway to extend this methodology.

АНАЛІЗ РИЗИКІВ ТА КРИТИЧНИХ КОНТРОЛЬНИХ ТОЧОК (НААСР), ПРИ ВИРОБНИЦТВІ М’ЯСНИХ КОВБАС НА ПП «CТРИЙСЬКІ ДЕЛІКАТЕСИ»

Meats include the main type of meat products. Great value and distribution of sausages due to their high nutritional valuation, calorie consumption opportunity without culinary processing a significant shelf life and the ability to transport over long distances. During the production of raw sausages remove parts that have low nutritional value (bones, connective tissue), and add substance to nutritionally valuable (dairy products, blood products, etc.) And have a good aroma and flavor properties (spices, etc.). Almost every food product that includes technology production element assembly recipes, can be attributed to the combination characteristic signs and indicators which will be determined in the primary content of the recipe specified product raw materials and manufacturing techniques. Therefore, in some countries, the products produced by the meat processing industry, classified on meat, meat combination, cereal (based on meat) and meat analogues. The main condition for the feasibility of achieving food remains its safety when consumed by man.The term "safety" means a guarantee that the full cycle of production, supply and storage of the product in terms not harm health.Article 20 of the Law of Ukraine «On the safety and quality of food» № 2809–IV of 6 September 2005 the requirement for persons engaged in the production or introduction into circulation of foodstuffs, apply sanitary measures and good practices of production, HACCP system and / or other systems to ensure safety and quality of food during the production and circulation of food. Almost all countries to food producers put forward similar demands.Due to possible prospects and expand markets, fatherland, his enterprises must increasingly implement certification system (security) product line with the recommendations of international legislation on the certification of food products (ISO 22000: 2005) systems Eurep GAP control in the crop, a system of control points for livestock and food production – hazard analysis critical control points (HACCP), which translates as «hazard analysis and critical control points». The main purpose of the article is the analysis of food safety, including cooked sausages, analysis of the presence of hazards throughout the production chain link on the example P.C. «SMIO» «Stryjsky meats delicious».

The design of large packaging production line system based on Embedded Technology

A design of jumbo packaging production line system based on embedded technology, through the STC89C52 microcontroller as the core control chip, rational allocation of the various modules, and the hardware selection and circuit design, system of jumbo packaging production line and the simulation presented in view of the problems in the present jumbo packaging production line of low degree of automation. Through study and design of jumbo packaging line control system, and through the experiment validation were used to collect the test data, verify the theoretical derivation and system design of correctness. Through the analysis of experimental data, test results and theoretical analysis results are consistent, indicating the reliability of the jumbo packaging production line system. At the same time, it is found that the accuracy of the synchronous rotation of the servo motor is compared with that of the fuzzy PID control algorithm and the common control algorithm. Therefore, it is concluded that the fuzzy PID control algorithm in the multi motor synchronous control effect is good, more able to meet the design requirements.

Automation of Soda Ash Handling System using PLC and SCADA in Glass Production Line

Automation is a one of the most popular technology. Now a day’s all production based industries need automation, because it gives more advantages over manual control system such as it reduce the man power, it reduces the operational errors, it reduce the failure rates, Easy to trouble shoot the system, it reduce the maintenance cost, it eliminate the hard wiring, it gives less rejection etc. The main aim of the paper is to automate the soda ash handling system in glass production line at leading glass production industry. The glass production line all systems are controlled by DCS (Distributed control system) but some sub systems are controlled by electromechanical relay system (Hard wired control system). The relay control system looks toward many issues. To limit that issues the system change from relay control system to PLC (Programmable logic controller) control system, because it gives more advantages over relay control system. In this proposed system all parameters are controlled, processed and monitored with help of Allen Bradley PLC and Wonderware intouch SCADA software.

Lot-sizing in a multi-stage flow line production system with energy consideration

In this paper, a single-item capacitated lot-sizing problem in a flow-shop system with energy consideration is studied. The planning horizon is defined by a set of periods where each one is characterised by a length, an allowed maximal power, an electricity price, a power price and a demand. The objective is to determine the quantities to be produced by each machine at each period while minimising the production cost in terms of electrical, inventory, set-up and power required costs. For medium- and large-scale problems, lot-sizing problems are hard to solve. Therefore, in this study, two heuristics are developed to solve this problem in a reasonable time. To evaluate the performances of these heuristics, computational experiments are presented and numerical results are discussed and analysed.