Manufacturing Process Management Research Articles

A Samsung production system-based approach to improve manufacturing process management in Vietnamese firms

Today, more and more Vietnamese firms consider continuous improvement as the best way to increase their manufacturing capability. This paper aims to illustrate the effectiveness of manufacturing processes management from the Samsung production system (SPS) approach when it was implemented to improve capability of existing production process in Vietnamese firms. The paper is a combination of descriptive and field research to demonstrate how SPS principles are appropriate for five real industry cases in particular and all Vietnamese manufacturing companies in general. In five cases, the usage of SPS-based tools has turned out to be fruitful. They solved problems of continuous improvement management in Vietnamese firms and created significant achievements in quality improvement and productivity increase. The paper investigates the core value of Samsung’s continuous process improvement. The way that Samsung has used to improve quality and profitability simultanously can be adapted by manufacturing companies.

Analysis of the Use of Agile Methods, Tools and Techniques in Foundry Enterprises

Abstract In an increasingly volatile environment, the importance of agile management, which should be based on flexible procedures and agile strategy, is increasing. The purpose of the study was to analyze the trend of development, level of knowledge and implications with the application of agile methods, techniques in project, program and manufacturing process management tools, as well as to identify areas of activity of foundry companies in the context of increasing the efficiency of their operations through the use of agile project approach. The completed research indicated that the knowledge and variety of application of agile methods, tools and techniques is at a relatively low level within the framework of project, program and manufacturing process management in the surveyed foundries. Among the most commonly used instrumentation are: PDCA, Kanban, SCRUM, SCRUMBAN, Lean Development, DMAIC and XP. The research showed that the use of agile instrumentation in the areas of projects, programs and manufacturing process management allows work to be done in an orderly and transparent manner. Foundries that consistently use agile instrumentation produce high-quality and non-conformity-free products with short time-to-market. Future research directions will be to perform a comparative analysis of the level of knowledge and implications of agile instrumentation in foundries located in Poland and selected neighboring countries.

Blockchain-based quality management for a digital additive manufacturing part record

Quality management (QM) of additive manufacturing (AM) processes is currently immature in terms of transparency, traceability and security. In particular, quality-relevant documents are not documented and communicated in a traceable and transparent manner, which often leads to quality deficiencies. However, combining AM with blockchain technology can enable a solution that maps the AM value chain digitally, transparently, traceably and securely in a part record. In this work, a quality assurance (QA) concept for the metal-based material extrusion (MEX) process is developed that enables a digital representation of the value chain in the form of an AM part record. The decentralized solution presented in this work uses an architecture consisting of a web application for data acquisition, a decentralized storage solution for storing larger amounts of data, a smart contract for capturing manufacturing events and the Ethereum blockchain for transparent, secure and traceable storage of blockchain data. The AM part record enables traceable and constantly available digital documentation of quality information. The cost-effectiveness of the solution is also shown in a demonstration study. The research results highlight the benefits of a blockchain-based AM part record for digital manufacturing documentation and represent an efficient alternative or extension to existing QM and QA solutions in AM.

Adaptive convolution confidence sieve learning for surface defect detection under process uncertainty

Surface defect detection plays an important role in the quality management of industrial manufacturing processes. Existing detection methods are developed based on clean and uncontaminated training data, less considering the process uncertainty. This paper proposes an adaptive convolution confidence sieve learning method for surface defect detection under process uncertainty. First, an edge-separated wavelet transform method combines the spatial and transform domain methods to estimate image noise. After that, an adaptive convolution model integrates parallel multiple convolution kernels, which can cover the defect feature variation. Then, a confidence sieve learning scheme is developed to filter the label noise, and the adaptive convolution is fine-tuned on the high-confidence data to achieve better detection accuracy. Finally, experimental studies on three industrial datasets have verified that the edge-separated wavelet transform method can accurately predict image noise. The adaptive convolution has better representation capability, and the confidence sieve learning improves model robustness.

Engineering and process management-based design of Comprehensive Biotechnology Experiment course

Based on the demand of enterprise talents and the characteristics of manufacturing process management in biotechnology, in order to make the students acquire the ability to solve complex engineering problems in the production process, we developed a "Comprehensive Biotechnology Experiment" course, where two-step enzymatic production of l-aspartate and l-alanine were the key processes. In this course, we drew lessons from the site management of the production enterprise, performed the experimental operation mode of four shifts and three operations. The content of this course includes principles, methods and experimental techniques of several core curricula and the site management mode of enterprises. As to the evaluation, the summary of the experimental staff's handover records and the content of teamwork were examined and scored. Through teaching practice and continuous improvement, we developed a complete experimental teaching process and assessment mechanism. Overall, the Comprehensive Biotechnology Experiment course achieved good teaching effect, which may serve as a reference to promote the development of experimental teaching of biotechnology.

DISCIPLINARY RESPONSIBILITY OF CREDIT INSTITUTIONS EMPLOYEES

The urgency of the research is due to existing features of implementing the institute of disciplinary responsibility in the field of labor and legal relations in credit institutions. The discipline of labor in credit institutions is developing in line with the trends characteristic of modern manufacturing process management. The general line is standardization of the manufacturing process to the extent that self-sufficient organizational forms that do not require manual control appear, following which is provided to the self-discipline of the employee (standard or matrix organizational solutions). Against the background of the ongoing changes, the issue of the employee's relative freedom and his responsibility to the employer, who no longer controls the labor process point-by-point – in the spirit of the industrial era, is raised. Despite the obvious features of labour organization for credit institutions employees, no special research has been conducted in the domestic legal science on the problems of implementing disciplinary responsibility. The author makes conclusions on the need to adopt a Labor Procedural Code, which will single out: the procedure for bringing to responsibility for misconduct committed under the conditions of the employer's current control over the quality of work and compliance with the process of its execution, as well as the specifics of bringing to responsibility for offense committed in conditions of relative freedom (without the employer's current control); forms of guilt as a mandatory sign of a disciplinary offense and the specifics of its definition if the employer's task involves an independent choice of its execution method (relative freedom of the employee); principles of proving guilt and innocence in examining the circumstances of a disciplinary offense; standardization disciplinary decisions, conditions and limits of its use; the procedure for using electronic document management in disciplinary proceedings; rules for interviewing third parties in disciplinary proceedings, rules for these persons' access to information about the state of affairs in the institution (or the entrepreneur, if he is the employer); rules for the protecting the information about disciplinary offenses, their circumstances, penalties applied.

Mathematical modeling of production process using cluster analysis methods

Manufacturing process management is a complex problem characterized by decision-making throughout the entire production process and is reduced to finding the best set of possible (alternative) in terms of some criterion or criteria for the use of available resources. The goal of the production process optimization is to analyze a set of alternative production options in complex systems and to determine the most rational possible state depending on the selected management strategies. The system contains many connections between elements and is influenced by random factors. It is not possible to create a real model for the system that is described analytically, but it can be investigated by using simulation modeling. In the mathematical modeling of the production process cluster analysis methods are used which allow to process a large amount of data from all possible states of the system and divide them into similar aggregates according to several characteristics. The analysis of the formed groups is carried out and the regularities that have the most significant impact on the occurrence of states into clusters are revealed.

Value of the 3D Product Model Use in Assembly Processes: Process Planning, Design, and Shop Floor Execution

Organizations can enhance the value of their assembly planning, assembly design, and assembly shop floor execution through the use of the 3D product model. Once a tool targeted at product design, the 3D product model, enabled by current and emerging manufacturing process management technologies, can create additional value for organizations when used in assembly processes. The research survey conducted and described in this paper demonstrates the value organizations have seen in using the 3D product model in the assembly process. The paper also explores the current state of those organizations who have not yet implemented the use of the 3D product model in their assembly processes and the value that they foresee for possible future implementation. The essential findings of this research are the five qualitative areas in which value is derived from using the 3D product model in complex assembly processes and how those value drivers apply across various industries and organization sizes. These results provide a framework for future research to develop quantitative models of the value of the 3D product model use in assembly processes.

The Most Important Cog in the Machine: Business Analysis and 5S Implementation in an Engineering Company

The focus of this paper is the 5S process, incorporating a real working example of how this method can positively affect a business in terms of managing change and continuous improvement. The benefits that 5S implementation can bring to a manufacturing business focus on every-day work with a holistic approach that intends to bring order both in the material environment and in the ethical values that support it. There are many factors that should be addressed when introducing 5S into a company, including some less tangible ones like moral and ethical principles, environmental factors, sustainability, and risk management. The backgrounds of the project featured in this work is in the field of nuclear waste management. The development of 5S practices are significant to this field because the methodology is known to increase safety and improve overall performance. However, it is also important to analyse what other aspects 5S could impact in an engineering company in this business.This work will therefore investigate the wider aspects of engineering management practice before delving into more specific questions on manufacturing process improvement with a particular focus on the impact 5S will have on workshop organisation and changing operator and technician culture. This will include a discussion of an industry relevant project and how 5S has impacted it. The project in question is entitled Soffit Plate Project and is a batch production project where a quantity of 282 Soffit plates are assembled with over 100 components in each plate. In total there are thousands of components that need to be managed throughout the contract with added paperwork and manufacturing process management as required. The work evidences that a normal approach would not be sufficient or sustainable for profitability and that 5S should be implemented from the beginning. The discussion focuses on the implementation of 5S and its effect on engineering business management. Keywords: 5S, introducing lean, lean manufacturing, process improvement, kaizen, SWOT, McKinsey 7S DOI: 10.7176/IEL/11-2-04 Publication date: June 30 th 2021

ПРОЕКТИРОВАНИЕ ТЕХНОЛОГИЧЕСКОГО ОБОРУДОВАНИЯ ДЛЯ АДДИТИВНОГО И СУБТРАКТИВНОГО ПРОИЗВОДСТВА

The analysis of design stages of technological equipment for traditional production is carried out, the features of the formation of technological equipment are studied using flows of energy and consumables. Structural synthesis of mechatronic complexes in digitalized production made it possible to add new stages to the process of creating technological equipment for both traditional automated subtractive manufacturing and new additive manufacturing. The processes of manufacturing parts without shape-generating molding tools, described by the algorithms according to the proposed structural diagram of connections, provide an opportunity to analyze existing and develop new methods of laminate synthesis of products. It is shown, how in the design of technological equipment for their use in new additive and traditional subtractive manufacturing, methods and schemes of laminate synthesis and shaping of parts from composite materials are used, based on the application of various energy flows and material components, as well as methods and schemes of automation and computer product manufacturing process management.

A novel robot co-worker system for paint factories without the need of existing robotic infrastructure

This paper presents a human–robot co-working system to be applied to industrial tasks such as the production line of a paint factory. The aim is to optimize the picking task with respect to manual operation in a paint factory. The use of an agile autonomous robot co-worker reduces the time in the picking process of materials, and the reduction of the exposure time to raw materials of the worker improves the human safety. Moreover, the process supervision is also improved thanks to a better traceability of the whole process. The whole system consists of a manufacturing process management system, an autonomous navigation system, and a people detection and tracking system. The localization module does not require the installation of reflectors or visual markers for robot operation, significantly simplifying the system deployment in a factory. The robot is able to respond to changing environmental conditions such as people, moving forklifts or unmapped static obstacles like pallets or boxes. The system is not tied to specific manufacturing orders. It is fully integrated with the manufacturing process management system and it can process all possible orders as long as their components are placed into the warehouse. Real experiments to validate the system have been performed in a paint factory by a real holonomic platform and a worker. The results are promising from the evaluation of performance indicators such as exposure time of the worker to raw materials, automation of the process, robust and safe navigation, and the assessment of the end-user. • The implemented robot co-worker system has been fully integrated into the business process of a paint factory. • The localization module implemented does not require the installation of visual markers. • The robot is able to respond to changing environmental conditions. • The system has been deployed with a real robot in a real environment.

MEACS-2020

International Conference on Mechanical Engineering, Automation and Control Systems 2020 (MEACS-2020) was successfully held on September 17, 2020. Initially, the conference was planned to be held in March, as part of the exhibition of equipment for metalworking and welding “MashExpo Siberia 2020” in Novosibirsk. However, due to the lockdown and all the restrictions associated with the coronavirus pandemic, MEACS-2020 was postponed until autumn. The conference was hosted by Novosibirsk State Technical University (Novosibirsk, Russia). Today, Novosibirsk is one of the largest scientific centers in Russia and in the Commonwealth of Independent States.MEACS-2020 provided an opportunity for researchers and practitioners to present and discuss up-to-date developments and innovations in the fields of mechanical engineering, automation of production processes, materials science, and industrial engineering. The participants presented papers on the issues of technological machines and equipment, mechanics and mechatronics, materials science in mechanical engineering, manufacturing process management, automation and optimization of production engineering.After careful reviewing, the most significant and valuable papers were accepted for publication. The volume consists of 79 relevant manuscripts. They present a wide range of technical solutions for automated mechanical engineering, and prospects for using information technologies and modeling methods in engineering.We would like to express gratitude to the Organizing Committee for hosting MEACS-2020, despite the unfavourable epidemiological situation. We would also like to thank all the participants and the editors for their valuable contribution in preparing the MEACS-2020 proceedings. We hope that readers would find this volume relevant and useful. On behalf of the editors, Vadim Skiba, Nikita Martyushev List of Programme Committee and Organizing Committee are available in this pdf.

Manufacturing process management for cast iron brake blocks

In order to insure a proper management in cast iron foundries it is necessary to coordinate all the processes that are involved in manufacturing cast parts. The organisation management offers the necessary conditions for developing activities, with great emphasis on the activity of quality control. The paper presents the necessity of establishing a management strategy which can lead to the supervision of the entire manufacturing cycle of cast iron brake blocks for rolling stock. To this end, it is necessary to measure, monitor and analyze the results obtained in the industrial practice and to compare them with product standards.

Integration of MBSE and PLM: complexity and uncertainty

Currently, MBSE and PLM methods and solutions are not well aligned with each other resulting in excessive complexity and uncertainty. Their full-scale integration would facilitate the development of complex systems. Better data flow from conceptual design to detailed design and feedback from later stages of product development are needed. In this paper, we analyse the MBSE and PLM integration from a system of systems (SoS) perspective and apply some of the methods used in systems engineering to better understand their nature, quantify their epistemic uncertainty and propose possible solutions to reduce their complexity and uncertainty. To achieve these goals, we study systems ontologies, such as the object-process methodology (OPM), the core product model (CPM), and manufacturing process management (MPM), which represent essential elements of a digital engineering solution. We also propose a measure of complexity to better quantify the structure of the interfaces through the design structure matrix (DSM)-based approach.

Design of mechatronic technological complexes for traditional and additive manufacturing

The analysis of the stages and stages of the design of technological equipment for traditional production, studied the features of the formation of technological equipment using flows of energy and consumables. Structural synthesis of mechatronic complexes in digitalized production allowed adding new stages to the process of creating technological equipment for both traditional automated subtractive and new additive manufacturing. The processes of manufacturing parts without shaping equipment described by the algorithms according to the proposed structural diagram of connections provide an opportunity to analyze existing and develop new equipment in laminate synthesis of products. It is shown, how in the design of technological equipments for their use in new additive and traditional subtractive manufacturing, methods and schemes of laminate synthesis and shaping of parts from composite materials are used, based on the use of various energy flows and material components, as well as methods and schemes of automation and computer product manufacturing process management.

GERT-network optimization model for technologies of hazardous industry management

The paper introduces GERT-network optimization model for the technologies of hazardous manufacturing process management supported by the software of distributed production control systems. The development and implementation of the formal means for optimizing processes for the formation of managing hazardous industries using GERT-networks technology is presented. It allows to include into the model random deviations and uncertainty arising directly during the execution of each separate task of hazardous industries management technology.

Criterios de asignación de gastos para el soporte técnico en la industria manufacturera de línea blanca

Recibido: 10 de agosto de 2019Aprobado: 30 de agosto de 2019En la actualidad muchas empresas manufactureras manejan la gestión por procesos sin encontrar la manera de integrarlos con su entorno; la presente investigación no experimental propone un documento competente a la asignación de gastos para el soporte técnico de una industria manufacturera de línea blanca, puesto que el mismo aporta en la organización de los procedimientos de una empresa; y especifica las actividades a realizar, aportando a la eficiencia y eficacia de las actividades, que son medidas por indicadores. En la investigación se determina los beneficios de la implementación de un documento técnico de las características descritas recayendo en la fiabilidad de la información ingresada al sistema informático disminuyendo las desviaciones presupuestales, identificando oportunidades de mejora continua y realizando trasferencia tecnológica. Como consecuencia se propone un documento base técnica de consulta para los criterios de los procedimientos de requisición y orden de compra aportando al cumplimiento de los indicadores de presupuesto.

Development and applications of a material library for pharmaceutical continuous manufacturing of solid dosage forms.

The purpose of this study is to establish a material library and discuss its potential application to the development and lifecycle management of a continuous manufacturing process for solid dosage forms. Particularly, this study addresses the importance of selecting process-relevant testing conditions for material characterization, proposes a methodology to capture relevant information with a reduced set of measurements, and correlates material properties with process performance. This study included 20 pharmaceutical materials, and each material was characterized by 44 properties, capturing 880 data points. The stress conditions of a commonly used feeder hopper were calculated using the Janssen model for six selected materials. Multivariate analysis, such as principal component analysis and clustering analysis, was used to explore the knowledge space of the material library. Statistically similar and dissimilar material properties were evaluated for material feeding performance from a loss-in-weight feeder to test utility of the material library. 20 materials included in this study show a wide range of material properties. Consolidation stress during testing significantly impacts obtained material properties. Based on a material similarity metric, a reduced set of characterization tests that captures >95% of the relevant information was identified. Materials were then grouped into six clusters. The material loss-in-weight feeding results show that the materials within the same cluster show similar feeding performance, while selected materials from different cluster have different feeding performance. Additional material understanding regarding flow properties may be needed to implement a continuous manufacturing process. Characterization using multiple tests under process-relevant conditions can be helpful to establish the correlation between material properties and process and product performance using multivariate analysis tools.

Hierarchical scheduling problem in the field of manufacturing operational planning

The paper considers a job shop scheduling problem similar to those taking place in many fields such as project management, educational sphere and operational planning of manufacturing process. The considered problem, in real life, has high dimensionality and it is quite hard to find even a feasible solution, therefore, making necessary a problem-oriented heuristic for solving it in reasonable time. Manufacturing process stability requires special care about restriction and, at the same time, operational planning requires finding solutions quickly. In this paper, hierarchical problem structure is proposed where the top-level problem is the traveling salesman problem and the nested resource-constrained project scheduling problem is replaced by the simulation model. This paper considers combinatorial genetic algorithm (GA) and Lin-Kernigan heuristic (LKH). The performance comparison is fulfilled and competitive results are demonstrated.

Hybrid data-driven physics-based model fusion framework for tool wear prediction

An integral part of modern manufacturing process management is to acquire useful information from machining processes to monitor machine and tool condition. Various models have been introduced to detect, classify, and predict tool wear, as a key parameter of the machining process. In more recent developments, sensor-based approaches have been attempted to infer the tool wear condition from real-time processing of the measurement data. Experiments show that the physics-based prediction models can include large uncertainties. Likewise, the measurement-based (or sensor-based) inference techniques are affected by sensor noise and measurement model uncertainties. To manage uncertainties and noise of both methods, a hybrid framework is proposed to fuse together the results of the prediction model and the measurement-based inference data in a stepwise manner. The fusion framework is an extension to the regularized particle filtering technique, used to facilitate updating the state prediction with a numerical inference model, when measurement models alone are not satisfactory. The results show significant improvement in tool wear state estimation, reducing the prediction errors by almost half, compared to the prediction model and sensor-based monitoring method used independently.